JP6856077B2 - Information display system in casting equipment - Google Patents

Description

The present invention relates to an information display system in a casting facility, and particularly to an information display system that displays information of a device at a distant position, which is necessary information for an operator.

The casting is obtained by molding a mold, transporting the mold to a pouring position, and pouring the mold into the mold. For this purpose, the casting equipment has a device for adjusting molding sand, molding a mold, and feeding the mold. In addition, there is an apparatus in which a hot molten metal melted in a melting furnace is received in a pot, the received pot is transported to a pouring position, and the hot water is poured into a mold at the pouring position. In addition, there is a device that cools the molten metal in the mold and separates the casting product from the mold sand. These devices have different performances required for each casting, and the arrangement of each device is also different.

Therefore, each device is designed and manufactured, and each device is equipped with a PLC that is exclusively controlled. Therefore, the actual situation is that the workers of the casting equipment obtain the information for each device from the display placed on each device and operate it. Therefore, there is a demand for a display device that allows an operator to check information on the entire equipment at a glance.

For example, in Patent Document 1, information from a molding machine, that is, a plurality of sensors for measuring data related to a molding device and a sand characteristic measuring machine for measuring data of kneaded sand input to the molding device is transmitted to a remote location. A molding-related information monitoring system to be displayed on a remote unit is disclosed.

Further, Patent Document 2 discloses a display device in which a display screen is installed at a high position of the injection molding device and can be visually recognized from a distant position.

In the invention disclosed in Patent Document 1, the worker cannot confirm the displayed information unless he / she goes to the place where the remote unit is installed. Further, as described above, the casting equipment is composed of various devices and the site is large, but Patent Document 1 only discloses a system for one device called a molding device. That is, in order to obtain information on another device, the information is obtained using the system of that device.

Further, the invention disclosed in Patent Document 2 only displays the information of one device, and is incomplete for displaying the information of the equipment having a plurality of devices such as a casting facility.

Therefore, an object of the present invention is to provide an information display system capable of obtaining necessary information in a place where an operator is normally working.

Japanese Patent No. 3480713 JP-A-2007-45126

In order to solve the above problems, the information display system according to the first aspect of the present invention molds the mold M and conveys the mold M to the pouring position P6, for example, as shown in FIGS. 1, 6 and 7. At the same time, in the casting facility 1 for obtaining a casting by pouring water into the mold M, the information display system 100 that displays information on a plurality of devices 10 and 30 constituting the casting facility 1 is at least one of the casting facilities 1. To display on the screen the device control PLC 102 that controls the device 10 and stores information about the device 10, and information about the plurality of devices 10 and 30, which is stored in the plurality of device control PLC 102. A computer 106 having a program for converting into screen display data of the above, and a display screen 108 for displaying information stored in the device control PLC 102 based on the screen display data obtained by the program of the computer 106. Information about the plurality of devices 10 is displayed on one screen so that the person can grasp the information of the entire casting facility 1. With this configuration, an operator of equipment having a plurality of devices such as a casting facility can obtain information on the plurality of devices from one display device, and can grasp information on the entire casting facility. Here, "the information of the entire casting equipment can be grasped" means that the casting equipment, each unit such as a molding unit, a mold transfer unit, and a pouring unit, or a molding machine, a kneading machine, and a pouring machine. It means that each device such as a machine, a surface treatment device, a dust collector, and a melting furnace can be operated, and the information required by a worker for adjusting operating conditions can be obtained.

In the information display system according to the second aspect of the present invention, in the information display system according to the first aspect, for example, as shown in FIGS. 1 and 6, the apparatus control PLC 102 is a sensor 12 installed in the apparatus 10. Memorize the information measured in. With this configuration, a time series of measured information can be obtained and the time series information can be displayed.

In the information display system according to the third aspect of the present invention, in the information display system according to the first or second aspect, as shown in FIG. 1, for example, the information stored in the device control PLC 102 is displayed on the screen. The computer 106 further includes an information storage PLC 104 that converts the information to be displayed, and the computer 106 converts the information stored in the information storage PLC 104 into screen display data. With this configuration, the computer converts the information from the information storage PLC converted into the information to be displayed on the screen into the screen display data, so that the load on the computer is reduced and the display can be performed quickly. ..

In the information display system according to the fourth aspect of the present invention, in the information display system according to the third aspect, for example, as shown in FIG. 1, the device control PLC 102 and the information storage PLC 104 are connected via a switching hub 110. Is connected by LAN. With this configuration, information on the device control PLCs of the plurality of devices is appropriately transmitted to the desired information storage PLC, so that necessary information can be selected. Further, when having a plurality of display screens, a screen for displaying the information can be selected.

In the information display system according to the fifth aspect of the present invention, in the information display system according to any one of the first to fourth aspects, the information displayed on the screen includes casting production information, device operation information, and the like. One or more of the molding sand information and the inspection standard information are included. With this configuration, the operator can obtain the information necessary for the operation of the casting equipment.

In the information display system according to the sixth aspect of the present invention, in the information display system according to the fifth aspect, the production information of the casting includes the planned production number, the current production number, the achievement rate, the defect rate, the model number and the product number. Contains one or more pieces of information. With this configuration, the operator can obtain the information necessary for the production of the casting.

In the information display system according to the seventh aspect of the present invention, in the information display system according to the fifth or sixth aspect, the operation information of the apparatus includes the operation status of the casting equipment, the cycle time for molding the mold, and the mold. Contains one or more pieces of information about the cycle time for pouring. With this configuration, the operator can obtain the information necessary to operate the plurality of devices.

In the information display system according to the eighth aspect of the present invention, in the information display system according to any one of the fifth to seventh aspects, the molding sand information includes the temperature, CB value, moisture, air permeability and air permeability of the molding sand. It contains one or more pieces of information about the compressive strength and the temperature of the atmosphere. With this configuration, the operator can obtain the necessary information about the molding sand.

In the information display system according to the ninth aspect of the present invention, in the information display system according to any one of the fifth to eighth aspects, the inspection reference information includes a product number, a model number, a lot number, and the model. Contains one or more pieces of visual inspection criteria corresponding to numbers and lot numbers. With this configuration, the operator can obtain the necessary information about the molding sand.

In the information display system according to the tenth aspect of the present invention, in the information display system according to any one of the first to ninth aspects, a second computer other than the computer is connected to the display screen by a LAN. The information stored in the second computer is displayed on the display screen. With this configuration, the operator can obtain from one display device, including useful information other than the casting equipment from the second computer.

In the information display system according to the eleventh aspect of the present invention, in the information display system according to any one of the first to tenth aspects, for example, as shown in FIGS. 1, 6, 7, 8, and 12. The casting equipment 1 includes a molding unit 10 for molding a mold M from mold sand, a mold transfer unit 30 for transporting the molded mold M, and a pouring unit for pouring hot water into the mold M conveyed by the mold transfer unit 30. The 70 and a casting equipment management computer 91 for controlling the casting equipment 1 are provided. The molding unit 10 includes a molding device 14 for molding the mold M and a molding unit control device 11 for controlling the operation of the molding device 14. The molding unit control device 11 receives the molding plan data from the casting equipment management computer 91, controls the molding device 14 so as to mold the mold M with the molding plan corresponding to the molding plan data, and also controls the molding device M so that the molding M is completed. A mold serial number is issued to the mold serial number, and the molding data related to the mold M is associated with the mold serial number. The mold transfer unit 30 includes a transfer mechanism 38 that transfers the mold M one mold at a time, a mold position detection sensor 39 that detects that the mold M has been transferred, and a mold transfer unit control that controls the operation of the mold transfer unit 30. It has a device 31 and. The mold transfer unit control device 31 controls the transfer mechanism 38 so as to intermittently transfer the mold M, and receives the mold serial number of the mold M which has been molded by the molding device 14 and is in a state where it can be transferred by the transfer mechanism 38. By shifting the mold serial number assigned to the mold position where the mold M stops according to the movement of the mold M detected by the mold position detection sensor 39, the mold position and the mold serial number of the mold M at the mold position are shifted. To correspond. The pouring unit 70 includes a pouring machine 72 for pouring molten metal from the pouring ladle L2 into the mold M, and a pouring unit control device 71 for controlling the operation of the pouring machine 72. The pouring unit control device 71 receives the ladle serial number associated with the molten metal state data of the molten metal in the pouring pot L2, and receives the mold serial number of the mold M at the pouring position P6 from the mold transfer unit control device 31. Is received, the pouring machine 72 is controlled so that the pouring plan corresponds to the pouring plan data corresponding to the mold serial number, and the pot serial number of the pouring ladle L2 is used as a mold. It is transmitted to the casting equipment management computer 91 in association with the serial number, and the molding data associated with the mold serial number and the mold serial number, and the ladle serial number and the molten metal state data associated with the molten metal state data are displayed on the display screen. Displayed at 108.

With this configuration, the information about the mold is associated with the mold serial number issued for each mold, and the mold serial number at the position where the mold stops is shifted every time the mold is conveyed. By doing so, you will understand. In addition, the information about the molten metal is associated with the ladle serial number for each ladle. Then, when the molten metal is poured into the mold by the pouring machine, the mold serial number of the mold at the pouring position and the ladle serial number of the poured ladle are associated and sent to the casting equipment management computer. That is, it is possible to manage the data related to the mold and the molten metal state data of the molten metal in combination by using the mold serial number and the ladle serial number associated with the mold serial number. Conventionally, in a casting factory, a molding device, a mold transfer device, a molten metal transfer device, a water pouring machine, and the like are individually controlled, and the operator controls each device to operate the entire casting facility. In particular, since a large number of molds are continuously molded and transported, it is difficult to grasp the situation in which each mold is being transported and to identify and manage the position thereof. Therefore, we focused on identifying and managing the positions of the individual molds to be transported. We also focused on managing the molten metal for each ladle that transports the molten metal. Furthermore, in the management method of mold molding data and molten metal state data in the information management of casting equipment, information about the mold is collected while grasping the situation where the mold is transported for each mold, and information about the molten metal is collected. Can be collected while grasping the situation in which the ladle is transported for each ladle, and when the molten metal is poured into the mold, the information on the mold and the information on the molten metal can be combined and managed. It is also possible to manage the data related to the molding apparatus in association with the mold molded by the molding apparatus. Furthermore, individual molds on the molding line can be identified and managed. The worker can obtain the information managed in this way from one screen.

In the information display system according to the twelfth aspect of the present invention, in the information display system according to the eleventh aspect, for example, as shown in FIGS. 1, 6, 7, and 12, a molding device 14 for molding the mold M The device control PLC 102 of the mold transfer device 30 is also used by the molding unit control device 11, and the device control PLC 102 of the mold transfer device 30 that conveys the mold M to the pouring position P6 is also used by the mold transfer unit control device 31 to pour hot water into the mold M. The device control PLC 102 of the hot water pouring device 72 also serves as the hot water pouring unit control device 71. With such a configuration, the operator can obtain necessary information regarding the molding device for molding the mold, the mold transfer device for transporting the mold to the pouring position, and the pouring device for pouring the mold.

According to the present invention, since an operator of a facility having a plurality of devices such as a casting facility can obtain information on the plurality of devices from one display device, it is necessary even in a place where a normal work is performed, for example. You will be able to obtain various information.

This application is based on Japanese Patent Application No. 2016-234182 filed on December 1, 2016 in Japan, the content of which forms part of the content of this application.
Also, the present invention will be more fully understood by the following detailed description. However, detailed description and specific examples are preferred embodiments of the present invention and are provided only for purposes of explanation. This is because various changes and modifications are obvious to those skilled in the art from this detailed explanation.
The applicant has no intention of presenting any of the described embodiments to the public and is equivalent to any of the disclosed modifications or alternatives that may not be literally included in the claims. It is a part of the invention under the theory.
In the description of the specification or claims, the use of nouns and similar demonstratives should be construed as including both singular and plural unless otherwise indicated or expressly denied by the context. The use of any of the exemplary or exemplary terms provided herein (eg, "etc.") is merely intended to facilitate the description of the invention and is not specifically stated in the claims. As long as it does not limit the scope of the present invention.

FIG. 1 is a system diagram showing a connection example of a plurality of information devices. FIG. 2 is a diagram showing a configuration example of a screen for displaying production information. FIG. 3 is a diagram showing a configuration example of a screen for displaying operation information. FIG. 4 is a diagram showing a configuration example of a screen for displaying information on mold sand. FIG. 5 is a diagram showing a configuration example of a screen for displaying an appearance inspection standard. FIG. 6 is a plan view showing the configuration of a casting facility, showing a casting facility in which hot water is received from a furnace in a processing ladle, replaced with a pouring ladle, and poured into a mold molded from the pouring ladle. FIG. 7 is an enlarged view of part A of FIG. FIG. 8 is a diagram showing a mold feed pusher that conveys a mold and a sensor that detects the operation thereof. FIG. 9 is a side view of the hot water receiving carriage with an empty replacement function. FIG. 10 is a side view of the pouring ladle carrier. FIG. 11 is a side view of the water pouring machine. FIG. 12 is a block diagram showing data acquired by each unit of the casting equipment and data communication between the units. FIG. 13 is a schematic view illustrating how the mold serial numbers are shifted. FIG. 14 is a schematic diagram illustrating the position of the ladle, the ladle serial number, and the molten metal state data associated with the ladle serial number. FIG. 15 is a flowchart showing the flow of data in the casting equipment. FIG. 16 is a plan view showing the configuration of a casting facility, showing a casting facility in which hot water is received from a furnace into a hot water ladle and then poured into a mold molded from the hot water ladle. FIG. 17 is an enlarged view of part B of FIG. FIG. 18 is a side view of a hot water ladle carrier with an elevating function.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In each figure, devices that are the same as or correspond to each other are designated by the same reference numerals, and duplicate description will be omitted. First, with reference to FIG. 1, an information display system 100 for displaying information on a plurality of devices constituting a casting facility as an embodiment of the present invention will be described. In the figure, although a plurality of devices constituting the casting equipment are omitted, reference numeral 102 indicates a device control PLC 102 provided in each device. The device control PLC 102 controls the operation of each device and stores information about each device. Further, the device control PLC 102 stores the information measured by the sensors installed in each device. Here, each device is, for example, a molding device, a kneader, a water pouring machine, a surface treatment device, a dust collector, a melting furnace, or the like, or a molding unit, a mold transfer unit, a molten metal transfer unit, which will be described later. , Pouring unit, etc., and is not limited thereto. Further, the information about each device includes, but is not limited to, information about the specifications of each device, information about the operating state of each device, and the like. Further, "memorizing information" means that information can be acquired and then output, and the memorizing time may be minute. The sensors installed in each device include, for example, sand input weight, compressibility, static pressure or squeeze pressure, squeeze time, boosting speed, squeeze stroke, mold thickness, molding time, etc. at the time of molding installed in the molding device. It is a sensor (measuring instrument) that measures the molding history data of, but is not limited to these.

The plurality of device control PLCs 102 are LAN-connected to the plurality of information storage PLCs 104 via the switching hub 110, and the plurality of information storage PLCs 104 have a computer 106 and a display screen 108, each of which has a program for converting into screen display data. LAN connection to. For example, when a certain device control PLC 102 and a switching hub 110 are in a good line-of-sight position, or when a switching hub 110 and a certain information storage PLC 104 are in a good line-of-sight position, the wireless communication device 112 is used. You may connect by wireless LAN. However, a wired LAN connection is preferable because the communication reliability is high. The device control PLC 102 and the information storage PLC 104 may be LAN-connected via a simple hub instead of the switching hub 110.

The information storage PLC 104 converts the information received from the device control PLC 102 into information for display on the display screen 108. The conversion here means, for example, collecting information on related devices into one table or graph, or arranging time-series information of the same type, but is not limited thereto. The computer 106 may perform the conversion process without providing the information storage PLC 104.

The computer 106 converts the data for screen display on the display screen 108 based on the information received from the information storage PLC 104. The information may be received directly from the device control PLC 102. The computer 106 has a program for converting data for screen display. This conversion program may be general-purpose software such as GOT (registered trademark, manufactured by Mitsubishi Electric).

The display screen 108 displays predetermined information using the data converted by the computer 106. The display screen 108 is preferably a large display of, for example, 25 inches (25 inches) or more. By displaying the information on the large display, the operator can visually recognize the displayed information without approaching the display screen 108.

FIG. 2 shows an example of displaying the production information of the molding apparatus. In the example of FIG. 2, the planned number of production, the number of production up to now, the achievement rate with respect to the planned number, the number of defective products generated, the model number (pattern No.) of the current production, the next time, the next time, the next time, the part number, The number of production and the planned number up to now are displayed. Production information is not limited to these.

FIG. 3 shows an example of displaying the operation information of the molding unit. In the example of FIG. 3, the presence or absence of abnormality, whether or not automatic operation is in progress, operating status (during sand recovery operation, post-processing operation, mold extrusion waiting, hot water pouring wait, 82PS line waiting, hot water pouring machine waiting, etc.), line The cycle time and FCMX cycle are displayed. In addition, "82PS line waiting" means a state in which the pusher cannot proceed with the pushing process due to the state of the post-process in the frame disassembling process. Further, the "FCMX cycle" means an operating time of one cycle of a molding machine (for example, "FCMX" manufactured by Shinto Kogyo Co., Ltd.). Operation information is not limited to these.

FIG. 4 shows an example of displaying information on the mold sand. In the example of FIG. 4, the atmospheric temperature, sand temperature, CB value (compactability), moisture, air permeability, and compression strength are displayed. In addition, "MIE-II" indicates the state of kneaded sand measured by a compactness control device (for example, "MIE-II" manufactured by Shinto Kogyo Co., Ltd.), and "IDST" is automatic raw sand characteristics. The state of the kneaded sand immediately before the molding machine measured by the measuring device (for example, "IDST" manufactured by Shinto Kogyo Co., Ltd.) is shown. Information on mold sand is not limited to these. The worker of the molding apparatus can confirm the production information of the molding apparatus, the operation information of the mold molding unit, and the information of the mold sand shown in FIGS.

FIG. 5 shows a display example of the appearance inspection standard for the mold. In the example of FIG. 5, the appearance inspection standard is displayed together with the model number and the lot number. When the visual inspection standard cannot be displayed on one screen, it may be displayed on multiple pages. The worker who performs the visual inspection can confirm the visual inspection standard document suitable for the product from the place where he / she usually works.

In the information display system 100, the information of various devices can be appropriately switched and displayed. A plurality of sets of the information storage PLC 104, the computer 106, and the display screen 108 are provided, and the information displayed on the display screen 108 is arranged at a position where the operator can see the information displayed on the display screen 108 from the place where the operator normally works. Then, for example, by operating a computer or by operating a remote controller, the screen can be switched so as to display necessary information. Alternatively, the display screen may be automatically and periodically changed so as to sequentially display the information required by the worker. Further, in the switching hub 110, it is possible to select a data transmission destination according to which device information, that is, which device control PLC 102 information needs to be displayed on which display screen 108.

Further, in the information display system 100, the operator can change the operation of each device via the device control PLC 102 by using the computer 106. That is, the command input to the computer 106 is sent as data in the LAN to the predetermined device control PLC 102 via the switching hub 110 to control the device.

Further, in the information display system 100, the display screen 108 may be installed so that the information necessary for the administrator, not the operator, can be confirmed from the place where the administrator normally performs his / her duties. As the information necessary for the manager, for example, information such as an abnormality occurrence status, production delay, defect rate, replacement time of consumables, quality control information, and energy consumption is displayed.

Further, a computer (not shown) other than the apparatus control PLC 102, the information storage PLC 104, and the computer 106 described above is connected to the display screen 108, and useful information other than the information of the casting equipment, for example, a casting product. It may be possible to display criteria, etc. regarding.

In this way, by using the information display system 100, workers and managers of equipment having a plurality of devices such as casting equipment can obtain necessary information from one display device in a place where they are normally working. This can greatly improve work efficiency.

Next, a configuration example of the casting equipment 1 in which the information display system 100 according to the present invention is used will be described with reference to FIGS. 6 and 7. FIG. 6 is a plan view showing the configuration of the casting equipment, and FIG. 7 is an enlarged view of part A of FIG. The casting equipment 1 includes a molding unit 10, a mold transfer unit 30, a molten metal transfer unit 50, and a pouring unit 70. The molding unit 10 molds the mold M from the mold sand. The mold transfer unit 30 transports the molded mold M from the molding unit 10 to the pouring unit 70, and cools the mold M poured by the pouring unit 70 while transporting the molten metal to cool and solidify the molten metal. The casting is made, and the casting is taken out from the mold by the mold disassembling device 48. The molten metal transfer unit 50 puts an alloy material into the processing ladle L1, receives hot water from the furnace F into the processing ladle L1, reacts the molten metal with the alloy material, and empties the molten metal after the reaction into the pouring ladle L2. Instead, the pouring ladle L2 is transferred to the pouring machine 72 of the pouring unit 70. The pouring unit 70 pours hot water from the pouring ladle L2 into the mold M.

The molding unit 10 has a pre-molding sand characteristic measuring instrument 12 for measuring the properties of the mold sand before molding. The mold sand before molding is, for example, kneaded by mixing raw sand or sand discharged from the mold disassembling device 48 with a sand recovery device with a binder, an additive, a hardening agent, water, and the like. It's sand. The properties of the mold sand greatly affect the quality of the mold, so measure it before molding.

The molding unit 10 has a molding device 14 for molding a mold from mold sand. In the molding apparatus 14, casting sand is put around a model that imitates the shape of a product, and two upper and lower molds are formed for one product. There are two types of molds: a mold with a frame made inside the mold and a mold without a frame without a mold. The molding device 14 is a measuring instrument (not shown) that measures molding history data such as sand input weight, compressibility, static pressure or squeeze pressure, squeeze time, boosting speed, squeeze stroke, mold thickness, and molding time at the time of molding. Have.

The molding unit 10 has a marking device 16 for marking a space formed on a mold by a model, that is, a surface of a space where molten metal is poured and solidified into a casting, that is, an inner surface, which is identifiable for each space. You may. The marking device 16 may, for example, cut a plurality of hole-shaped marks on the surface of the space of the mold with a jig such as a drill while changing the mutual positional relationship, or may mark holes and grooves with a laser or the like. You may. When, for example, a hole is formed on the inner surface of each space of the mold, a protrusion is formed on the surface of the cast casting at a position corresponding to the hole, and it becomes possible to identify each casting. Here, the reason for each space of the mold is that one mold may make a plurality of castings. That is, one mold has a plurality of spaces. That is, by engraving on the surface of each space of the molded casting, the engraving is formed corresponding to each obtained casting. The marking device 16 may be provided in the mold transfer unit 30. However, it is easier to engrave immediately after molding the mold, for example, in the case of a self-hardening sand mold, because the engraving can be performed before it is completely cured and the mold is not broken. In particular, in the case of a frameless mold, marking is performed by the marking device 16 while the mold is inside the molding device 14.

The mold transfer unit 30 has a mold rail Rf for transporting the mold M from the molding unit 10 to the pouring unit 70, cooling the mold M while transporting the mold M, and transporting the mold M to the mold disassembling device 48. The mold rails Rf are arranged in parallel as shown in FIG. 6, for example, and the molds M are laterally moved between the rails Rf and are alternately conveyed in opposite directions by the plurality of rails Rf. Therefore, the mold M after pouring is cooled over time, and the molten metal is solidified before reaching the mold disassembling device 48 to form a casting. That is, the transport path of the mold transport unit 30 is transported to be poured from the molding line 32, which processes the mold molded by the molding device 14, into a completed mold in a state where hot water can be poured, and the hot water pouring machine 72. The mold transfer unit is roughly divided into a mold transfer unit pouring zone 33 and a mold transfer unit cooling zone 34 in which the poured mold M is transported and cooled over time.

The mold transfer unit 30 has a mold feed pusher 38 as a transfer mechanism shown in FIG. 8 at the end of a straight line of the rail Rf. The pusher 38 is a device that expands and contracts the rod to push the mold, for example, an air cylinder, a hydraulic cylinder, or an electric cylinder. The pusher 38 is a sensor that detects the expansion and contraction of the rod, and has a mold position detection sensor 39 that detects that the mold M is conveyed. The mold position detection sensor 39 may be a limit switch, a proximity switch, a photoelectric switch, or the like. The pusher 38 preferably has a mold position detecting encoder 37 in order to perform synchronous pouring or to correctly detect the pouring position even if the thickness of the mold changes. The pusher 38 pushes the molds at the rear ends arranged on the straight rail Rf by one frame, and intermittently conveys the arranged molds one frame at a time. It is preferable to install the pusher 38 on the opposite side (front end) of the straight rail Rf and to contract the rod as it is pushed by the rear end. With this configuration, a row of molds M can be suppressed from both ends during transportation, and the molds M are stable during transportation. When the mold M reaches the front end, it is transferred onto the adjacent rail Rf by the traverser T, and is set as the rear end at the mold line there. The traverser T may also be provided with a mold position detection sensor 39.

The molding line 32 of the mold transfer unit 30 further has a gas hole drilling device 40, and drills holes in the mold for removing gas generated when hot water is poured. The molding line 32 further includes an upper and lower mold reversing machine 41, for example, reversing the upper and lower molds to direct the mold space upward. The molding line 32 further has a sand cutter 42 that removes excess sand from the upper surface of the upper mold and the lower surface of the lower mold to flatten it. The molding line 32 further has a sprue cutter 43, and a sprue is opened in the upper mold.

The molding line 32 further has a surface plate trolley setting device 44, and mounts the mold on the surface plate trolley. The molding line 32 further has a core setter 45 and sets cores in the upper and lower molds. The molding line 32 further has an upper mold re-inverting machine 46, and is aligned with the direction in which one mold is formed when the upper mold is inverted and the upper and lower molds are overlapped. The molding line 32 further has a mold matching / mold transfer device 47, and the upper mold and the lower mold are combined to form an upper and lower completed mold in a state where hot water can be poured. The order of the devices from the gas drilling device 40 to the core setter 45 is not limited to the above, and can be replaced as appropriate.

When the mold is a mold with a frame, the mold transfer unit 30 includes a gas hole drilling device 40, a vertical mold reversing machine 41, a sand cutter 42, a sprue cutter 43, and a surface plate trolley setting device 44, as shown in FIG. 6, for example. A core setter 45, an upper mold re-inverting machine 46, and a mold matching / mold transfer device 47 are provided, and the mold M molded by the molding device 14 is processed into a top-bottom completed mold in a state in which hot water can be poured. When the mold is a frameless mold, the molding apparatus 14 may perform processing such as forming a degassing hole, setting a core, and aligning the mold. In that case, the mold transfer unit 30 processes the mold. It is not necessary to provide some or all of the devices 40 to 47 for the purpose.

The mold transfer unit 30 has a mold disassembling device 48. In the mold disassembling device 48, the mold is disassembled, the casting is taken out, and the casting and the sand are separated. The casting is then shipped as a product through a post-process. The core is also separated. The sand is reused for a mold by removing mixed iron powder, a binder and the like with a sand recovery device (not shown).

The molten metal transfer unit 50 includes an alloy material charging unit 60 for charging an alloy material to react with the molten metal into the processing ladle L1. The alloy material unit 60 has a plurality of alloy material hoppers 62, and one or more kinds of alloy materials are charged into the processing ladle L1. Alternatively, the alloy material and the molten metal are mixed with a wire inoculation device (not shown) in which the treatment ladle L1 is covered with a hole and a thin pipe filled with the alloy material is inserted into the molten metal in the treatment ladle L1 through the hole in the lid. You may react. The alloy material unit 60 includes a measuring instrument (not shown) and a timer (not shown) for measuring the weight of the alloy material charged from each alloy material hopper 62 into the processing ladle L1.

The molten metal transfer unit 50 replaces the molten metal with the charging position P1 at which the alloy material is charged from the alloy material charging unit 60 into the processing ladle L1, the hot water receiving position P2 for receiving the hot water from the furnace F, and the molten metal pouring pot L2. It has a hot water receiving carriage 52 with an empty changing function for transporting the processing ladle L1 to the empty changing position P4, and a rail R on which the hot water receiving carriage 52 with an empty changing function travels. When the alloy material and the molten metal are reacted by wire inoculation, the wire inoculation position is the charging position P1. In addition, the description "when the alloy material is put in" shall be read as "when the wire is inoculated". The alloy material includes Mg, Ce, Ca, Ni, Cr, Cu, Mo, V, Ti, etc. added to the molten metal to improve the strength and toughness of cast iron, corrosion resistance, heat resistance, wear resistance, etc. To say. The alloy material contains a graphite spheroidizing agent. Further, an inoculant such as calcium silicon, ferrosilicon, or graphite may be added to the alloy material input unit 60.

As shown in FIG. 9, the hot water receiving carriage 52 with an air change function includes a traveling carriage 520 traveling on the rail R and a traveling motor 522 for traveling the traveling carriage 520. An encoder 523 is provided on the wheels of the traveling carriage 520, and the rotation of the wheels, that is, the traveling of the traveling carriage 520 is measured. That is, the encoder 523 is a ladle position detection sensor capable of detecting the position of the processing ladle L1. The hot water receiving carriage 52 with an empty replacement function may be provided with a pan position detection sensor 59 (see FIG. 7) such as a photoelectric sensor described later. The hot water receiving carriage 52 with an empty replacement function includes a tilting device 526 that tilts the processing ladle L1 to replace the molten metal, and a tilting motor 527 for tilting the processing ladle L1 using the tilting device 526. The tilting device 526 and the processing ladle L1 are placed on the scissor lifter 524 on the traveling carriage 520 and moved up and down. Since the hot water receiving carriage 52 with an empty replacement function has a function of raising and lowering the processing ladle L1, it becomes easy to replace the processing ladle L1 with the pouring ladle L2. The hot water receiving carriage 52 with an empty replacement function has a load cell (first weight scale) 525 that measures the weight of the molten metal received from the furnace F. It also has a non-contact thermometer (not shown) that measures the temperature of the molten metal received.

In the hot water receiving carriage 52 with an empty replacement function, by installing the cable reel 528 and the control panel 521 that receive power from the outside at a position away from the processing ladle L1, the molten metal can be discharged from the processing ladle L1. In case of leakage, it does not affect these devices. The control panel 521 may be installed not on the traveling carriage 520 but at a position along the rail R on which the traveling carriage 520 travels.

When the molten metal is put into the processing ladle L1 into which the alloy material is charged and the alloy material reacts with the molten metal, droplets of the molten metal are scattered and dust and gas are generated. Therefore, when the alloy material in the processing ladle L1 reacts with the molten metal, the processing ladle L1 is conveyed to the reaction position P3. A reaction chamber (not shown) may be provided at the reaction position P3. The reaction chamber surrounds the upper part of the processing ladle L1 and discharges air through a duct. Therefore, it is possible to prevent the droplets of the molten metal from scattering to the surroundings and to discharge dust and dust.

As shown in FIG. 10, the molten metal transfer unit 50 has the same reference numeral for convenience, although it is different from the empty replacement position P4 in which the molten metal can be emptied from the processing ladle L1 (strictly speaking, it is different from the empty replacement position P4 of the processing ladle L1). ), And the pouring ladle transport trolley 54 for transporting the pouring ladle L2 to the transfer position P5 for transferring the pouring ladle L2 to the pouring machine 72, and the pouring ladle transport trolley 54 travel. It has a rail R. The hot water ladle transport cart 54 has a traveling carriage 540 traveling on a rail, a roller conveyor 544 installed on the traveling carriage 540, and a roller conveyor 544 and a roller conveyor motor 546 that move the hot water ladle L2 in the horizontal direction. An encoder 543 is provided on the wheel of the traveling carriage 540, and the rotation of the wheel, that is, the traveling of the traveling carriage 540 is measured. That is, the encoder 543 is a ladle position detection sensor that can detect the position of the pouring ladle L2. In the pouring ladle carrier 54, by installing the cable reel 548 and the control panel 541 that receive power from the outside at a position away from the pouring ladle L2, the molten metal should be melted from the pouring ladle L2. In case of leakage, it does not affect these devices. The control panel 541 may be installed not on the traveling carriage 540 but at a position along the rail R on which the traveling carriage 540 travels. Further, the hot water ladle transport mechanism 58 (see FIG. 7) that transports the hot water ladle L2 between the transfer position P5 and the hot water pouring machine 72 in a direction orthogonal to the traveling direction of the hot water ladle transport cart 54 (see FIG. 7). May be installed. The pouring ladle transport mechanism 58 may be a roller conveyor or the like. The capacity of the treatment ladle L1 may be doubled, for example, the capacity of the pouring ladle L2, and one treatment ladle L1 may be replaced with two pouring ladle L2.

An empty inoculation device 56 for adding an inoculant to the molten metal to be replaced from the treatment ladle L1 to the pouring ladle L2 may be provided near the empty replacement position P4. The configuration of the air replacement inoculation device 56 is basically the same as that of the alloy material input unit 60. By adding the inoculant when the molten metal is emptied from the treatment ladle L1 to the pouring ladle L2, the inoculant can be uniformly added in a short time.

In the molten metal transfer unit 50, the processing ladle L1 was transported to the charging position P1, the hot water receiving position P2, the reaction position P3, and the empty replacement position P4 as the ladle position of the processing ladle L1, and the hot water intake. It has a ladle position detection sensor 59 that detects that the pouring ladle L2 has been transported to the empty replacement position P4 and the transfer position P5 as the ladle position of the ladle L2. As shown in FIG. 7, the pan position detection sensor 59 may be a proximity switch or a laser sensor installed under the roller conveyor of the pouring pan transfer mechanism 58, for example. Alternatively, the encoders 523 and 543 installed on the hot water receiving trolley 52 with an empty replacement function shown in FIG. 9 and the hot water ladle transport trolley 54 shown in FIG. 10 may be used, or the hot water receiving trolley 52 with an empty changing function may be used. Or a photoelectric sensor installed on the pouring ladle carrier 54. In addition, it has a photoelectric sensor for confirming that the processing ladle L1 is mounted on the hot water receiving trolley 52 with an empty replacement function and that the hot water ladle L2 is mounted on the pouring ladle transport trolley 54. Is preferable.

As shown in FIG. 11, the pouring unit 70 has a pouring machine 72 for pouring hot water from the pouring ladle L2 into the mold M. The water pouring machine 72 is supported by a water pouring machine trolley 720 that travels in parallel with the mold M to be poured, an elevating mechanism 722 installed on the water pouring machine trolley 720, and an elevating mechanism 722. A tilting mechanism 724 that tilts the mounted hot water ladle L2, a hot water pouring machine rail Rp on which the hot water pouring trolley 720 runs, and a load cell (second weighing scale) that measures the molten metal weight of the hot water pouring ladle L2. It has 725. The elevating mechanism 722 is installed on the front-rear moving mechanism 728 that moves in the direction orthogonal to the traveling direction of the water pouring machine trolley 720. It also has a non-contact thermometer (not shown) that measures the temperature of the molten metal to be poured. The non-contact thermometer is preferably of the fiber type, for example, so that the temperature measuring unit can be adjusted.

The water pouring machine 72 preferably has a hot water level detection camera 726 for detecting the hot water level at the sprue of the mold M. In this case, by providing a taper to the pouring cup of the sprue, the sprue level is detected from the area of the sprue photographed by the sprue surface detection camera 726. The hot water level detection camera 726 may be an image sensor. It is preferable that the sprue surface detection camera is supported (suspended) by an arm and can be moved in the horizontal direction so that the sprue surface can be photographed even if the position of the sprue changes.

As shown in FIG. 11, the pouring unit 70 preferably has a test piece (TP) collecting unit 76 that receives the molten metal for the test piece (TP) from the pouring ladle L2. In the TP collection unit 76, TP is collected from the molten metal of each pouring ladle L2 for material inspection.

As shown in FIG. 12, the casting equipment 1 includes a casting equipment management computer 91 that manages the entire casting equipment 1, and each unit is provided with a control device. That is, the molding unit control device 11 is used for the molding unit 10, the mold transfer unit 31 is used for the mold transfer unit 30, the molten metal transfer unit control device 51 is used for the molten metal transfer unit 50, and the molten metal transfer unit control device 51 is used for the molten metal transfer unit 70. The device 71 is provided. Further, the alloy material input unit 60 is provided with an alloy material input unit control device 61. The TP collection unit 76 may be provided with a TP collection unit control device. These control devices are installed in each unit, but the place where they are installed is not limited. For example, the molten metal transfer unit control device 51 may be composed of a control panel 521 of the hot water receiving carriage 52 with an empty replacement function and a control panel 541 of the hot water ladle transport carriage 54. Further, the pouring unit control device 71 may be installed on the pouring machine carriage 720 as shown in FIG. 11, or may be installed at a position along the pouring machine rail Rp. Physically, the plurality of control devices 11, 31, 51, 61, 71 may be in the same control device, or may be in the same computer as the casting equipment management computer 91. The casting equipment management computer 91 may be any computer capable of data management, and its configuration is not particularly limited. Alternatively, using cloud computing, the operation of each control device and the casting equipment management computer 91 may be performed by a computer at a location different from that of the casting equipment 1. In these cases as well, it is assumed that each unit is equipped with each control device, and the casting equipment 1 is provided with the casting equipment management computer 91.

These control devices 11, 31, 51, 61, 71 include the device control PLC 102 shown in FIG. Alternatively, each of the control panel 521 of the hot water receiving carriage 52 with an empty replacement function and the control panel 541 of the hot water ladle transport carriage 54 may include a device control PLC 102. Further, a device control PLC 102 may be installed in each device. Then, each of the control devices 11, 31, 51, 61, 71 is connected to the switching hub 110, and is connected to the display screen 108 via the information storage PLC 104 and the computer 106. Alternatively, the casting equipment management computer 91 may also function as a computer 106 having a program for converting the screen display data shown in FIG. 1. Then, the casting equipment management computer 91 may be connected to a display screen 108 that can be visually recognized from a place where the operator is normally working.

Next, the casting method and the data management method in the casting equipment 1 will be described with reference to FIGS. 6, 7, and 12. Based on the product plan, user input, etc., the molding plan data indicating the plan for molding the mold M with the molding unit 10, the mold M molded by the mold transfer unit 30 is conveyed, and the mold M is processed such as drilling. Transport plan data showing the plan, molten metal transport plan data showing the molten metal transport plan and replacement plan in the molten metal transfer unit 50, alloy material plan data showing the plan of the alloy material and injectant to be charged in the alloy material input unit 60, and , The pouring plan data indicating the pouring plan from the pouring pot L2 to the mold M in the pouring unit 70 is input to the casting equipment management computer 91, or is calculated by the casting equipment management computer 91. It should be noted that the molding plan data, the transfer plan data, the molten metal transfer plan data, the alloy material plan data, and the pouring plan data may be treated as a set of data by combining two or more. The molten metal transfer plan data and the alloy material plan data are collectively called the molten metal plan data.

The molding plan data includes data such as a model number, a mold release agent application time, a static pressure or a squeeze pressure at the time of molding, a sand input amount, a mold height, a mold thickness, and a compression ratio. The transport plan data includes data such as gas hole drilling, sprue shape and position, core set, and intermittent mold transport cycle time. The molten metal transport plan data includes data such as a material number and a hot water receiving weight planned value. The alloy material planning data includes data such as the hopper number and the input weight from the hopper. The pouring plan data includes data such as pouring weight, cup position, pouring temperature, allowable fading time and molten metal material corresponding to the mold.

The molding unit 10 molds the mold M based on the molding plan data. First, the properties of the mold sand before molding are measured with the pre-molding sand characteristic measuring machine 12. The properties to be measured include compactability (CB), moisture, sand temperature, air permeability, mold strength (counterpressure), and the like. The properties of the mold sand greatly affect the quality of the mold. The measured properties of the mold sand are stored in the molding unit control device 11 as molding history data.

Molds (upper mold and lower mold at this stage) are molded by the molding apparatus 14 using the mold sand whose properties have been measured. A mold release agent is applied to a predetermined model, a predetermined amount of mold sand is put in the mold, and the mold is pressed with a predetermined static pressure or a squeeze pressure until a predetermined compressibility is reached to form a mold having a predetermined thickness and height. When the mold is molded, the molding unit control device 11 issues a mold serial number to the mold. When the mold serial number is issued, the molding plan data such as the measured properties of the mold sand is associated with the mold serial number. Further, the molding apparatus 14 measures molding history data such as sand input weight, compressibility, static pressure or squeeze pressure, squeeze time, boosting speed, squeeze stroke, mold thickness, and molding time, and mold serial numbers are used as molding history data. Associate with. The molding unit control device 11 transmits the mold serial number and the molding history data to the casting equipment management computer 91. The molding plan data and the molding history data are collectively called molding data. Further, the molding unit control device 11 transmits the mold serial number and the molding data associated with the mold serial number to the mold transfer unit control device 31.

When the mold is molded by the molding apparatus 14, a mark for identifying the space is engraved on the inner surface of the space for manufacturing the casting in the mold by the engraving apparatus 16. Either the upper mold or the lower mold may be stamped. Further, when there are a plurality of spaces in one mold, that is, when a plurality of castings are manufactured by one mold, an identifiable mark is engraved in each space. That is, an identifiable mark is attached to each obtained casting (product). When the marking device 16 is used for marking, the molding unit control device 11 issues an individual identification serial number corresponding to each marking. Further, the molding unit control device 11 associates the issued individual identification serial number with the mold serial number. When the marking device 16 is installed in the mold transfer unit 30, the individual identification serial number is issued by the mold transfer unit control device 31 and is associated with the mold serial number by the mold transfer unit control device 31.

In the mold transfer unit 30, the mold M is conveyed based on the mold transfer plan data, the mold M is made ready to be poured, and the poured mold, that is, the molten metal is cooled to separate the casting and the sand. .. In the mold transfer unit 30, the pusher 38 intermittently feeds the mold one frame at a time. The traverser T also transfers the molds one by one to the next mold row. Further, a hole is drilled in the mold by the gas drilling device 40, the upper mold and the lower mold are inverted by the upper and lower mold reversing machine 41 to face the mold space upward, and the sand cutter 42 is used to remove excess sand on the upper surface of the upper mold. Remove and open the sprue in the upper mold with the sprue cutter 43. Further, the mold is placed on the surface plate by the surface plate set device 44, the core is set in the upper mold and the lower mold by the core setter 45, the upper mold is inverted by the upper mold re-inverting machine 46, and the mold is aligned. The mold transfer device 47 combines the upper mold and the lower mold to form one mold M. Historical data in these processes, such as gas hole drilling information, sprue hole drilling information, core information, etc., are collected as molding data (mold history data) and associated with the mold serial number. In this way, the mold transfer unit 30 collects molding data while transporting the mold. When a defect occurs in these processes, the mold transfer unit control device 31 associates the defect information with the mold serial number of the mold M. In the case of a frameless mold, part or all of the above gas hole drilling information, sprue hole drilling information, core information, etc. is obtained by the molding unit 10, and is associated with the mold serial number by the molding unit control device 11. May be done.

As shown in FIG. 13, the mold transfer unit control device 31 detects the transfer of the mold by the mold position detection sensor 39 each time the mold is transferred, and shifts the mold serial number. A mold serial number "n" is issued to the mold molded by the molding apparatus 14. When the mold transfer unit 30 detects that one frame of the mold has been transferred, the mold serial number "n" is shifted to the next position. Mold serial numbers are assigned to all the stop positions in the intermittent transfer of the mold, and by shifting all the mold serial numbers, the mold positions and the mold serial numbers correspond correctly.

The molten metal transfer unit 50 operates the hot water receiving carriage 52 with an empty replacement function and the hot water ladle transporting carriage 54 based on the molten metal transfer plan data. The empty processing ladle L1 is first conveyed to the charging position P1 by the hot water receiving carriage 52 with an empty replacement function. When the processing ladle L1 is conveyed to the charging position P1, the alloy material is charged from the alloy material charging unit 60 to the processing ladle L1. The alloy material may contain an inoculant.

In the alloy material charging unit 60, the alloy material is charged into the processing ladle L1 based on the alloy material charging plan data. When the alloy material is charged into the processing ladle L1, the alloy material charging unit control device 61 issues a ladle serial number to the processing ladle L1. Further, the alloy material charging history data such as the type, weight, and charging time of the alloy material charged from the alloy material charging unit 60 into the processing ladle L1 is associated with the pan serial number. When the ladle serial number and the alloy material input history data are prepared, the data is transmitted to the casting facility management computer 91. Further, at least the ladle serial number is transmitted to the molten metal transfer unit control device 51. The ladle serial number and the alloy material input history data may be transmitted to the molten metal transfer unit control device 51 without being transmitted to the casting facility management computer 91. In that case, the molten metal transfer unit control device 51 transmits the molten metal transfer unit control device 51 to the casting facility management computer 91 as the molten metal state data as the molten metal history data including those data. The molten metal state data may include molten metal planning data. If a problem occurs in the processing of the alloy material in the alloy material charging unit 60 into the ladle L1, the information on the problem is transmitted to the casting equipment management computer 91 in association with the pot serial number.

The processing ladle L1 into which the alloy material is charged is transported to the hot water receiving position P2 by the hot water receiving carriage 52 with an empty replacement function of the molten metal transport unit 50. The treatment ladle L1 receives the molten metal from the furnace F. When the molten metal is received, the weight of the molten metal received by the load cell 525 as the first weigh scale and the temperature measured by the non-contact thermometer are measured. The molten metal transfer unit control device 51 associates the measured weight, temperature, hot water discharge furnace number and charge number, material number, hot water reception time, and the like with the hot water ladle serial number of the processing ladle L1 as molten metal state data. Further, data on the properties of the molten metal melted in the furnace F may be received and the data may be included in the molten metal state data. The molten metal melted in the furnace, the molten metal received in the treatment ladle, and the molten metal that has reacted with the alloy material are simply referred to as "molten metal" in the present specification.

The hot water treatment ladle L1 is conveyed to the reaction position P3 by the hot water receiving carriage 52 with an empty replacement function. If the reaction between the molten metal and the alloy material is intense, the alloy material input unit 60 is used to charge the alloy material into the processing ladle L1, and then the alloy material is covered with a covering agent such as steel scrap to bring the molten metal into contact with the alloy material. suppress. Therefore, a violent reaction does not occur immediately after receiving hot water in the treatment ladle L1, and the treatment ladle L1 can be moved to the reaction position P3 during that time. Further, when the alloy material contains a spheroidizing element such as Mg, severe bubbling occurs when the reaction starts. Therefore, the measured value in the load cell 525 fluctuates greatly. Therefore, the time when the measured value in the load cell 525 fluctuates greatly and then becomes smaller than the predetermined value can be recognized as the start of fading. The molten metal transfer unit control device 51 may associate the faded elapsed time, which is the fading start time or the elapsed time from the fading start time, with the ladle serial number as the molten metal state data. The fading start time or elapsed time associated with the ladle serial number is transmitted to the pouring unit control device 71. In this way, the molten metal transfer unit control device 71 collects the molten metal state data while transporting the processing ladle L1 and the pouring ladle L2, and associates them with the ladle serial number.

When the reaction between the molten metal and the alloy material is completed, the processing ladle L1 is conveyed to the empty replacement position P4 by the hot water receiving carriage 52 with an empty replacement function. At the empty replacement position P4, the empty pouring ladle L2 is transported by the pouring ladle transport cart 54 and stands by. Therefore, the molten metal is emptied from the processing ladle L1 to the pouring ladle L2. Here, in the hot water receiving carriage 52 with an emptying function, the processing ladle L1 is set to a desired height by the scissor lifter 524, and the processing ladle L1 is tilted to be replaced, so that the treatment ladle L1 can be replaced safely and efficiently. During the transportation of the processing ladle 1, the processing ladle 1 can be lowered and moved to a position close to the center of the traveling carriage 520 to reduce the influence of the shaking of the traveling carriage 520.

When the emptying is completed, the ladle serial number associated with the processing ladle L1 is associated with the pouring ladle L2. After that, the hot water receiving carriage 52 with an empty replacement function conveys the processing ladle L1 to the charging position P1 and repeats from the charging of the alloy material. It should be noted that two hot water pouring ladle L2 and two hot water pouring machines 72 may be provided, and the molten metal may be emptied from one processing ladle L1 to two pouring ladle L2. When it takes a long time to pour hot water, the efficiency of the casting equipment 1 can be improved by pouring hot water from the hot water ladle L2 to the mold M using a plurality of hot water pouring machines 72. When one processing ladle L1 is replaced with two pouring ladle L2, the second ladle L2 is filled with the serial number of the processing ladle L1 and the second ladle. Data indicating that it is a replaced ladle is associated as a ladle serial number. An inoculant may be added from the empty replacement inoculation device 56 to the molten metal that is replaced from the processing ladle L1 to the pouring ladle L2. The molten metal transfer unit control device 51 associates the type and weight of the added inoculant and the addition time with the ladle serial number as the molten metal state data.

When the molten metal is emptied into the pouring ladle L2, the pouring ladle transport cart 54 transports the pouring ladle L2 to the transfer position P5. The hot water ladle L2 is transferred from the transfer position P5 to the hot water pouring position P6 by the hot water ladle transport mechanism 58, and is held by the hot water pouring machine 72. The molten metal transfer unit control device 51 transmits the ladle serial number and the molten metal state data associated with the ladle serial number to the casting facility management computer 91. If a problem occurs in the molten metal transfer in the molten metal transfer unit 50, the information on the problem is transmitted to the casting equipment management computer 91 in association with the serial number of the pot.

As shown in FIG. 14, the molten metal transfer unit 50 has a processing ladle L1 or a pouring ladle L2 at the charging position P1, the hot water receiving position P2, the reaction position P3, the empty replacement position P4, and the transfer position P5. The detection sensor 59 (or encoders 523, 543) detects it and shifts the ladle serial number. Then, the molten metal state data is associated with the ladle serial number. Therefore, the position of the processing ladle L1 or the pouring ladle L2 and the ladle serial number correctly correspond to each other, and the molten metal state data from different devices are correctly associated with the ladle serial number.

When the mold M is transported in front of the pouring machine 72, the mold transfer unit control device 31 transmits the mold serial number of the mold M to the pouring unit control device 71. Then, the pouring unit control device 71 receives the pouring plan data from the casting equipment management computer 91, and further, the hot water ladle serial number, the hot water receiving weight, and the allowable hot water receiving pot L2 from the molten metal transfer unit control device 51. Receives fading time, fading start time, fading elapsed time, etc. The pouring unit control device 71 may not receive the faded elapsed time, but may receive the faded start time to measure the faded elapsed time.

The pouring unit control device 71 determines the material of the molten metal, that is, the type and weight of the alloy material, the weight of the molten metal, etc., based on the pouring plan data corresponding to the mold serial number of the mold M. Compare with the material of the molten metal according to the molten metal state data corresponding to the number. When these two materials do not match, the pouring unit control device 71 issues an error signal. In this case, the molten metal is returned to the melting furnace F without pouring. The hot water ladle L2 may be suspended by a crane or the like and returned to the melting furnace F. Alternatively, a transfer device (not shown) for returning the molten metal to the melting furnace F may be provided and returned to the melting furnace F.

When the pouring ladle L2 is received by the pouring machine 72, the weight of the molten metal in the pouring ladle L2 is measured by the load cell 725 as the second weighing scale. The difference between the weight measured by the load cell 725 and the weight measured by the load cell 525 associated with the same ladle serial number is calculated, and when the difference is larger than a predetermined value, the pouring unit controller 71 issues an error signal. .. This is because there is a high possibility that the molten metal has spilled or leaked during transportation.

The pouring unit control device 71 pours molten metal from the pouring ladle L2 into the mold M based on the pouring plan data. Therefore, first, based on the height of the mold and the position of the sprue associated with the mold serial number, the pouring ladle L2 is moved to the mold M side by the front-back movement mechanism 728, and is moved up and down by the elevating mechanism 722. Then, while moving the pouring port of the pouring ladle L2 by the elevating mechanism 722 and the front-back moving mechanism 728, the pouring ladle L2 is tilted by the tilting mechanism 724 to pour hot water into the mold M.

The pouring unit control device 71 stores the pouring pattern, and pours the pouring in the pouring pattern applied to the mold associated with the mold serial number. During pouring, the sprue surface detection camera 726 acquires image data of the sprue. The pouring unit control device 71 calculates the pouring surface level based on the image data, and controls the tilting of the pouring ladle L2 by the tilting mechanism 724. Further, during pouring, the load cell 725 measures the weight of the molten metal in the pouring ladle L2, and the pouring unit control device 71 calculates the amount of the molten metal poured into the mold M. When the weight of the poured molten metal approaches the target value, drain the water. The mold M is intermittently conveyed even in front of the water pouring machine 72 as in other places. Therefore, if the pouring into the mold M is not completed during the stopped time, the water pouring machine trolley 720 travels at the same speed as the conveyed mold M and continues pouring into the mold M. be able to. Further, when the time for pouring water from the water pouring machine 72 is longer than the interval at which the mold is intermittently conveyed, two water pouring machines 72 are used. That is, two pouring ladle L2 are used.

The pouring unit control device 71 appropriately compares the elapsed fading time with the allowable fading time. When the elapsed fading time exceeds the allowable fading time, an error signal is issued, and even if the molten metal remains in the pouring ladle L2, the pouring from the pouring ladle L2 is stopped. Therefore, it is possible to prevent poor spheroidization due to fading. The molten metal remaining in the pouring ladle L2 is returned to the melting furnace F and reused by using a transport device for returning the molten metal to the melting furnace F.

The TP collection unit 76 receives the molten metal from the pouring ladle L2 and solidifies it as TP. The molten metal is received at the end from the pouring ladle L2, even before pouring from the processing ladle L2 into the first mold, after pouring into one mold and starting to pour into the next mold. It may be after pouring hot water into the mold. When the TP is collected, the pouring unit control device 71 issues a test piece (TP) serial number. The TP serial number is associated with the ladle serial number. The TP is then inspected for material, and the inspection result is associated with the TP serial number and transmitted to the casting equipment management computer 91. The TP collection unit 76 may have a TP collection unit control device and issue a TP serial number. In that case, the TP serial number is transmitted to the pouring unit control device 71, where it is associated with the ladle serial number. In this case, the TP collection unit control device is regarded as a part of the pouring unit control device 71. If there is a material defect in the TP inspection result, the TP serial number is transmitted to the casting equipment management computer 91. The ladle serial number is known from the TP serial number and is associated with the mold serial number, and the mold disassembling device 48, which will be described later, processes the mold serial number as a defective product when an error signal is associated with the mold serial number.

In the pouring unit control device 71, the number of molds poured from the same pouring ladle L2, the number of times in the ladle, the pouring (casting) time, the pouring pattern number, and the pouring (casting) weight Then, the time, pouring temperature, etc. are measured, and these data are associated with the ladle serial number as molten metal state data. Further, the mold serial number of the mold M is associated with the ladle serial number of the pouring ladle L2 that has poured water into the mold M. When the pouring unit control device 71 finishes these associations, the pouring unit control device 71 transmits the data to the casting equipment management computer 91. When a problem occurs in pouring water from the pouring ladle L2 to the mold M in the pouring unit 70, the information on the problem is transmitted to the casting equipment management computer 91 in association with the mold serial number.

In the mold transfer unit 30, the poured mold M is conveyed in the cooling zone 34. In the cooling zone 34, the rail Rf is long and it takes time to be conveyed. At that time, the molten metal in the mold M is cooled and solidified. When the mold M is conveyed to the mold disassembling device 48 downstream of the cooling zone 34, the mold M is disassembled and the casting and sand are separated. The casting is sent to a post-process to make it into a product. The sand is sent to the molding unit 10 via a sand recovery device (not shown). The mold transfer unit control device 31 does not send the separated casting to the subsequent process when the error signal associated with the mold serial number of the mold M transferred to the mold release device 48 and the TP inspection result are defective products. To distinguish. Therefore, it is possible to prevent defective products from being shipped as products. The mold transfer unit control device 31 associates a mold serial number with the casting sent to the subsequent process. Further, the mold serial number and the molding history data are transmitted to the casting equipment management computer 91.

The casting equipment management computer 91 stores the mold serial number, the molding data, the ladle serial number, the molten metal state data, and the TP inspection result. A mold serial number is associated with the mold manufactured in the casting equipment 1. A ladle serial number is associated with the mold serial number. Therefore, the mold serial number and the ladle serial number can be known from the casting product. Then, the mold molding data is associated with the mold serial number, and the molten metal state data is associated with the ladle serial number. Therefore, all historical data is associated with the foundry product. Therefore, when there is a product defect, the manufacturing history can be confirmed. Here, since the molten metal state data having a large amount of data can be managed for each pot and the data managed for each pot can be extracted from the mold serial number for each mold, the amount of data to be stored can be reduced.

When the individual identification serial number is issued corresponding to each space of the mold, the casting product can be specified by the individual identification serial number. Therefore, for example, when a defect is found by product inspection, the mold serial number can be extracted using the individual identification serial number of the casting product, and the mold history data and the molten metal state data can be known based on the mold serial number. it can. Therefore, it is possible to easily investigate the cause of the problem.

Here, with reference to FIG. 15, the work of performing the data processing of the mold unit and the work of performing the data processing of the ladle unit will be described together. Molding is performed by the molding apparatus 14 using the mold sand which has been subjected to sand treatment and whose properties have been measured by the sand characteristics before molding. A mold serial number is issued to the mold molded here, and thereafter, data processing for each mold is performed using the mold serial number. The shape of the mold and the like are exchanged by exchanging the casting frame, model and the like used in the molding apparatus 14. Gas hole drilling, raising frame reversal, sand cutting, sprue cutting, surface plate trolley set, core set, upper mold re-reversing, mold alignment, etc. as the process of processing into a molded mold use the data of the mold unit and history Is recorded in mold units.

When the alloy material is put into the processing ladle L1 mounted on the hot water receiving carriage 52 with an empty replacement function, a ladle serial number is issued to the processing ladle L1. After that, data processing is performed for each ladle using the ladle serial number. Moving the processing ladle L1 to the hot water receiving position P2, reaction position P3, and emptying position P4, receiving the molten metal from the melting furnace F, and moving to the pouring ladle L2 mounted on the pouring ladle transport cart 54. Replacing, moving the pouring ladle L2 to the transfer position P5, transferring the pouring ladle L2 to the pouring machine 72, pouring the hot water into the mold at the pouring machine 72, TP at the TP sampling unit 76 For collection, etc., data for each ladle is used, and history (state data) is also recorded for each ladle.

When hot water is poured into the mold by the water pouring machine 72, the ladle serial number is associated with the mold serial number, and the data associated with the ladle serial number can be extracted from the mold serial number. That is, since the cooling time of the mold in the cooling zone can be changed depending on, for example, the pouring weight of the molten metal, the pouring weight may be extracted from the mold serial number and the length transported in the cooling zone may be changed for each mold. Specifically, which traverser T is used to transfer the mold to the adjacent mold rail Rf, or which mold rail Rf is used to transfer the mold to the adjacent mold rail Rf may be changed. Further, when the mold is disassembled by the mold disassembling device 48, if the molten metal state data drawn from the mold serial number contains a defect, the disassembled casting is distinguished from the casting as a product, and is disposed of, for example. You can also do it.

Next, a casting facility 2 different from the casting facility 1 of FIG. 6 will be described with reference to FIGS. 16 and 17. In the casting facility 2, hot water is received from the furnace F into the hot water ladle L2 and transferred to the hot water pouring machine 72 without replacement. Since the other points are the same as those of the casting equipment 1, duplicate explanations will be omitted, and only the different points will be described. When the reaction between the molten metal and the alloy material is not so violent, it is not necessary to react in the treatment ladle L1, and the hot water can be received and reacted in the pouring ladle L2.

The molten metal transfer unit 50 includes an alloy material charging unit 60, a pouring ladle transport cart 84 that transports the pouring ladle L2 to the pouring position P1, the hot water receiving position P2, the reaction position P3, and the transfer position P5, and the pouring ladle. It has a rail R on which the pot transport carriage 84 travels, and a hot water ladle transport mechanism 58 that transports the hot water ladle L2 from the transfer position P5 to the hot water pouring machine 72. When the reaction is mild, the reaction position P3 may not be particularly determined, and the molten metal and the reaction alloy material may be reacted during transportation.

As shown in FIG. 18, the pouring ladle transport bogie 84 extends horizontally from the traveling bogie 840 traveling on the rail R, the guide pillar 842 installed on the traveling bogie 840, and the bogie 842. It has an elevating frame 844 that can be elevated and lowered above, a ladle moving mechanism 846 that is installed on the elevating frame 844 and moves the hot water ladle L2 in the horizontal direction, and an elevating frame elevating device 848 that elevates and elevates the elevating frame 844. The elevating frame elevating device 848 winds up the chain 848C by the rotation of the motor 848M and elevates the elevating frame 844. For example, even if the melting furnace F and the pouring unit 70 are constructed at different times and the installation heights are different, the pouring ladle carrier 84 has a function of raising and lowering the pouring ladle L2. The difference in height can be absorbed. The pouring ladle carrier 84 has a load cell (first metric) 845 that measures the weight of the molten metal received from the furnace F. It also has a non-contact thermometer (not shown) that measures the temperature of the molten metal received.

The pouring ladle carrier 84 is provided by installing a power receiving device 849 and a motor 848M that receive power from the outside at a high position and at a position away from the pouring ladle L2. If the molten metal leaks from L2, it does not affect these devices. The high position is a position higher than the bottom of the pouring ladle L2 when the pouring ladle transport carriage 84 is traveling, that is, when the elevating frame is lowered. The position away from the hot water ladle L2 is the position on the opposite side of the guide pillar 842.

Also in the casting equipment 2, when the alloy material is charged into the pouring ladle L2 from the alloy material charging unit 60, a ladle serial number is issued to the pouring ladle L2. The molten metal state data is associated with the ladle serial number, and after pouring water from the pouring machine 72 into the mold M, the ladle serial number is associated with the mold serial number. Therefore, the same effect as that of the casting equipment 1 can be obtained.

By using this information display system 100, the operator can obtain the mold serial number and the molding data associated with the mold serial number and the molten metal state data associated with the ladle serial number and the ladle serial number obtained in this way. Can be found in the place where you normally work. Therefore, each worker can perform the work in charge while grasping the information of the entire casting equipment 1, and the reliability of the work is remarkably improved.

The transfer of data between the unit control devices 11, 31, 51, 61, 71 and the casting equipment management computer 91 described in the present specification is not limited to the above, and may be changed as appropriate. The data shown as each planning data, template history data, and molten metal state data are examples, and other data may be used.

The main reference numerals used in the present specification and the drawings are summarized below.
1, 2 Casting equipment 10 Molding unit 11 Molding unit control device 12 Pre-molding sand characteristic measuring machine 14 Molding device 16 Engraving measure 30 Mold transfer unit 31 Mold transfer unit control device 32 Molding line 33 Mold transfer unit Pouring zone 34 Mold transfer unit Cooling zone 36 Mold transfer lane 37 Mold position detection encoder 38 Mold feed pusher (convey mechanism)
39 Mold position detection sensor 40 Gas hole drilling device 41 Upper and lower mold reversing machine 42 Sand cutter 43 Gate cutter 44 Plate plate trolley setting device 45 Core setter 46 Upper mold re-reversing machine 47 Mold alignment / mold transfer device 48 Mold disassembling device 50 Ladle transfer Unit 51 Hot water transfer unit control device 52 Hot water receiving trolley with empty replacement function 54, 84 Hot water ladle transport trolley 56 Air replacement infusion device 58 Pouring ladle transfer mechanism 59 Ladle position detection sensor 60 Alloy material input unit 61 Alloy material Input unit control device (alloy material input control device)
62 Alloy material hopper 70 Hot water pouring unit (molten metal transport unit)
71 Hot water pouring unit control device 72 Hot water pouring machine 76 Test piece (TP) sampling unit 91 Casting equipment management computer 100 Information display system 102 PLC for device control
104 PLC for information storage
106 Computer having a program to convert to screen display data 108 Display screen 110 Switching hub 112 Wireless communication equipment 520 Travel trolley 521 Control panel 522 Travel motor 523 Encoder (position detection sensor)
524 scissor lifter (elevating function)
525 load cell (1st weight scale)
526 Tilt device 527 Tilt motor 528 Cable reel 540 Traveling carriage 541 Control panel 542 Traveling motor 543 Encoder (ladle position detection sensor)
544 Roller Conveyor 546 Roller Conveyor Motor 548 Cable Reel 720 Water Pouring Machine Cart 722 Lifting Mechanism 724 Tilt Mechanism 725 Load Cell (2nd Weighing Scale)
726 Hot water level detection camera 728 Back and forth movement mechanism 840 Traveling trolley 842 Guide pillar 843 Encoder 844 Lifting frame 845 Load cell (1st weight scale)
846 Ladle moving mechanism 848 Lifting frame lifting device 849 Power receiving device F Melting furnace L1 Processing ladle L2 Pouring ladle M Mold P1 Filling position P2 Hot water receiving position P3 Reaction position P4 Empty position P5 Transfer position P6 Pouring position R rail Rf mold rail Rp water pouring machine rail T ladle

Claims (14)

An information display system that displays information on a plurality of devices constituting the casting facility in a casting facility that molds a mold, transports the mold to a pouring position, and pours the mold into a casting to obtain a casting. ,
A PLC for device control that controls at least one device of the casting facility and stores information about the device,
A computer having a program for converting information about the plurality of devices and stored in the plurality of device control PLCs into screen display data for displaying on the screen.
It is provided with a display screen that displays information stored in the device control PLC based on screen display data obtained by the computer program.
Information about the plurality of devices is displayed on one screen so that the operator can grasp the information of the entire casting facility.
Information display system. The device control PLC stores information measured by a sensor installed in the device.
The information display system according to claim 1. An information storage PLC that converts information stored in the device control PLC into information to be displayed on the screen is further provided.
The computer converts the information stored in the information storage PLC into the screen display data.
The information display system according to claim 2. The device control PLC and the information storage PLC are connected by a LAN via a switching hub.
The information display system according to claim 3. The information displayed on the screen includes one or more of the casting production information, the operation information of the apparatus, the molding sand information, and the inspection standard information.
The information display system according to claim 4. The production information of the casting includes one or more information among the planned production number, the current production number, the achievement rate, the defect rate, the model number and the product number.
The information display system according to claim 5. The operation information of the apparatus includes one or more information among the operation status of the casting equipment, the cycle time for molding the mold, and the cycle time for pouring hot water into the mold.
The information display system according to claim 6. The molding sand information includes one or more information among the temperature of the molding sand, the CB value, the moisture content, the air permeability and the compressive strength, and the temperature of the atmosphere.
The information display system according to claim 7. The inspection standard information includes a product number, a model number, a lot number, and one or more information among the appearance inspection standards corresponding to the model number and the lot number.
The information display system according to claim 8. A second computer other than the computer is connected to the display screen by a LAN, and the information stored in the second computer is displayed on the display screen.
The information display system according to claim 9. The casting equipment
Molding unit that molds mold from mold sand and
A mold transfer unit that conveys the molded mold, and
A pouring unit for pouring hot water into the mold conveyed by the mold feeding unit, and a pouring unit.
It is equipped with a casting equipment management computer that controls the casting equipment.
The molding unit includes a molding device for molding the mold and a molding unit control device for controlling the operation of the molding device.
The molding unit control device receives the molding plan data from the casting equipment management computer, controls the molding device so as to mold the mold with the molding plan corresponding to the molding plan data, and controls the molding device for the completed mold. Is issued a mold serial number, and the mold serial number is associated with the molding data related to the mold.
The mold transfer unit includes a transfer mechanism that transfers the molds one by one, a mold position detection sensor that detects that the molds have been transferred, and a mold transfer unit control device that controls the operation of the mold transfer unit. Have and
The mold transfer unit control device controls the transfer mechanism so as to intermittently transfer the mold, receives the mold serial number of the mold that has been molded by the molding device and is in a state of being able to be transferred by the transfer mechanism, and said. By shifting the mold serial number assigned to the mold position where the mold stops according to the movement of the mold detected by the mold position detection sensor, the mold position corresponds to the mold serial number of the mold at the mold position. Let me
The pouring unit includes a pouring machine for pouring molten metal from a pouring ladle into a mold, and a pouring unit control device for controlling the operation of the pouring machine.
The pouring unit control device receives the ladle serial number associated with the molten metal state data of the molten metal in the pouring ladle, and receives the mold serial number of the mold at the pouring position from the mold transfer unit control device. The pouring machine is controlled so that the pouring machine is received and the pouring plan corresponds to the pouring plan data corresponding to the mold serial number, and the ladle serial number of the pouring ladle is used as the mold. Send to the foundry management computer in association with the serial number
The mold serial number and the molding data associated with the mold serial number, and the ladle serial number and the molten metal state data associated with the molten metal state data are displayed on the display screen.
The information display system according to claim 1. The casting equipment
Molding unit that molds mold from mold sand and
A mold transfer unit that conveys the molded mold, and
A pouring unit for pouring hot water into the mold conveyed by the mold feeding unit, and a pouring unit.
It is equipped with a casting equipment management computer that controls the casting equipment.
The molding unit includes a molding device for molding the mold and a molding unit control device for controlling the operation of the molding device.
The molding unit control device receives the molding plan data from the casting equipment management computer, controls the molding device so as to mold the mold with the molding plan corresponding to the molding plan data, and controls the molding device for the completed mold. Is issued a mold serial number, and the mold serial number is associated with the molding data related to the mold.
The mold transfer unit includes a transfer mechanism that transfers the molds one by one, a mold position detection sensor that detects that the molds have been transferred, and a mold transfer unit control device that controls the operation of the mold transfer unit. Have and
The mold transfer unit control device controls the transfer mechanism so as to intermittently transfer the mold, receives the mold serial number of the mold that has been molded by the molding device and is in a state of being able to be transferred by the transfer mechanism, and said. By shifting the mold serial number assigned to the mold position where the mold stops according to the movement of the mold detected by the mold position detection sensor, the mold position corresponds to the mold serial number of the mold at the mold position. Let me
The pouring unit includes a pouring machine for pouring molten metal from a pouring ladle into a mold, and a pouring unit control device for controlling the operation of the pouring machine.
The pouring unit control device receives the ladle serial number associated with the molten metal state data of the molten metal in the pouring ladle, and receives the mold serial number of the mold at the pouring position from the mold transfer unit control device. The pouring machine is controlled so that the pouring machine is received and the pouring plan corresponds to the pouring plan data corresponding to the mold serial number, and the ladle serial number of the pouring ladle is used as the mold. Send to the foundry management computer in association with the serial number
The mold serial number and the molding data associated with the mold serial number, and the ladle serial number and the molten metal state data associated with the molten metal state data are displayed on the display screen.
The information display system according to claim 10. The molding unit control device also serves as the device control PLC of the molding device that molds the mold.
The mold transfer unit control device also serves as the device control PLC of the mold transfer device that transports the mold to the pouring position.
The PLC for controlling the device of the pouring device for pouring hot water into the mold also serves as the pouring unit control device.
The information display system according to claim 11. The molding unit control device also serves as the device control PLC of the molding device that molds the mold.
The mold transfer unit control device also serves as the device control PLC of the mold transfer device that transports the mold to the pouring position.
The PLC for controlling the device of the pouring device for pouring hot water into the mold also serves as the pouring unit control device.
The information display system according to claim 12.

Images