JPH0732132A - Method and device for assisting work in casting process - Google Patents

Abstract

PURPOSE:To keep the suitable casting condition and to produce a casting having high quality by using a computer based on the knowledge base made by the knowledges of experts and the detected data to execute an inference and controlling the quantity of state at the preceding step so as to execute the desired casting. CONSTITUTION:At the time of pouring molten metal into a mold by melting raw material in a melting furnace of a cupola, etc., physical or chemical data of the molten metal from the melting furnace, e.g. chemical component data 3, i.e., the composition is detected and the pouring temp. 4 of the molten metal at the time of pouring is detected. The inference is executed by using the computer based on the detected data and the knowledge base made by the knowledge of the experts. In this method, an indication output or control 5 to the charging step of the raw material containing the metal into the melting furnace, or an indication output or control 6 to the melting process in the melting furnace is executed so as to execute the desired casting.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a work support method and apparatus for a casting process.

[0002]

2. Description of the Related Art A typical prior art is JP-A-1-180.
774. In this prior art, when performing precision casting, casting is performed while the casting control factor and its appropriate control amount stored in the computer when the casting operation is started are read according to the casting sequence program.

Such a prior art does not perform processing based on the knowledge of an expert and is not directly related to the present invention. Moreover, this prior art relates to precision casting, and therefore, it does not perform casting by melting a raw material containing a metal using a melting furnace such as cupola and pouring the molten metal into a mold formed of foundry sand. It does not give instructions to the charging process of the metal to be charged into the melting furnace, the melting process during the operation of the melting furnace, and the kneading process of the molding sand for molding. In the casting process of pouring the molten metal from the cupola into the mold formed by the foundry sand, countermeasures when problems occur are caused by time lag, and it is not always possible for the operator to take appropriate measures. Also, it is difficult to convey the accumulated experience of skilled workers to new workers,
There is a problem that the casting quality changes when the operator changes.

Another prior art is Japanese Patent Laid-Open No. 63-116.
017, although this prior art discloses a device that uses an expert system for control of a sludge incinerator, it is in a completely different technical field and is not directly related to the present invention.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is that an operator is an amateur when pouring molten metal from a melting furnace such as cupola into a mold formed of foundry sand to perform a casting process. Also, work support to maintain appropriate casting conditions so that high-quality castings can be manufactured and appropriate measures can be taken promptly when problems occur during the process. A method and apparatus are provided.

[0006]

SUMMARY OF THE INVENTION The present invention is a casting process including the steps of charging a raw material containing metal into a melting furnace, melting the raw material in the melting furnace, and pouring the molten metal into a mold. In the work support method for a process, a step of detecting physical or chemical data in at least one of a raw material melting step and a pouring step,
Based on the knowledge base created based on the knowledge of the expert and the data detected in the detection step, a reasoning is performed using a computer, and the raw material charging step that is performed before that so that the desired casting is performed. Or a step of outputting a work instruction in the raw material melting step, or a step of controlling the state amount of the raw material charging step or the raw material melting step, and a work supporting method for a casting process.

Further, the present invention is a work support method for a casting process, comprising the steps of kneading molding sand and molding using the molding sand, the step of detecting physical or chemical data in the molding step, Based on the knowledge base created based on the knowledge of the expert and the data detected in the detection step, the inference is performed using a computer, and the casting sand kneading step is performed before that so that the desired casting is performed. And a step of controlling the amount of state of the casting sand kneading step in Step 1.

Further, the present invention detects the operation status of the melting furnace, the means for detecting the pouring status of pouring the molten metal from the melting furnace into the mold, and the status of molding using the molding sand. Means, display output or control means respectively provided at a place for charging a raw material containing metal into the melting furnace, a place for the melting furnace, and a place for kneading the foundry sand, an operation status detecting means, and a pouring status detecting means In response to the output of the molding situation detection means and the knowledge base created based on the expert's knowledge, the inference is performed using a computer so that the desired casting is performed, and the ingot is placed in the melting furnace. Indication output or control output means provided at the location for charging the raw materials to control or feed the raw material charging operation to achieve the desired operating conditions, and display output provided at the melting furnace location Or The control means instructs the output or control the operation of the melting furnace so as to pouring conditions desired,
Further, a work support device for a casting process, including means for outputting or controlling the kneading operation of the molding sand so that a desired molding condition is obtained by a display output or a control means provided at a place for kneading the molding sand. Is.

[0009]

As described above, according to the present invention, when the raw material is melted in a melting furnace such as a cupola and poured into a mold, physical or chemical data of the molten metal from the melting furnace, for example, chemical components, that is, The composition is detected, the pouring temperature of the molten metal at the time of pouring is detected, and based on such detected data and a knowledge base created based on the knowledge of experts, inference is made using a computer. Then, in order to carry out the desired casting, the instruction output or control for the step of charging the raw material containing the metal into the melting furnace or the instruction output or control for the melting process by the melting furnace is performed thereby. In this way, the operator can be instructed or the operating conditions can be controlled so that the desired casting process can be performed, and there is no time lag, and even if the operator is unfamiliar, high quality casting Can be manufactured.

Further, according to the present invention, when molding is performed using foundry sand, the physical or chemical data of the foundry sand, such as the properties of the sand, such as the wet property, are detected, and based on the knowledge of the expert. Based on the knowledge base created as described above and the above-mentioned detected data, when kneading the molding sand, a work instruction is output or controlled so that desired casting is performed. In this way, it becomes possible to maintain a suitable casting condition and manufacture a high quality casting.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is an overall system diagram of an embodiment of the present invention. For example, when melting / pouring cast iron,
A charging step S1 of charging a raw material containing a metal into the cupola 1 shown in FIG. 2, a melting step S2 of melting the charged raw material in a melting furnace, and a molten metal from the melting furnace 1 are transferred to the mold 2 The pouring step S3 of pouring (see FIGS. 2 and 8 described later) is achieved in this order. Each step S
In 2 and S3, the detection means 3 for detecting the operating condition of the melting furnace
And a detecting means 4 for detecting the pouring condition. Furthermore, a place for charging raw materials including metal into the melting furnace (Fig. 2
The display output or control means 5 such as a cathode ray tube is shown in FIG.
Further, a display output or control means 6 is provided at the location of the melting furnace 1.

In making the mold 2, a step R1 of kneading the foundry sand is performed, and then a molding step R2 of making a mold using the foundry sand is performed in this order. In the molding step R2, means 7 for detecting the molding situation is provided. A display output or control means 8 is provided at the location where the foundry sand is kneaded. The outputs of the detection means 3, 4, and 7 are given to a processing circuit 10 realized by a computer or the like via an interface 9. A memory 11 such as a hard disk is connected to the processing circuit 10 to store data, and a backup memory 12 using a magneto-optical disk or the like is connected. The output of the processing circuit 10 can be displayed by the display output means 13, and can also be printed on a recording paper by the printer 14 and displayed.

In response to the output of the operating condition detecting means 3 of the melting furnace 1, the processing circuit 10 causes the display output provided at the raw material charging place or the controlling means 5 to obtain the operating condition desired by the melting furnace 1. In addition, the raw material charging operation is instructed to be output or controlled. Further, the processing circuit 10 is operated by the display output or the control means 6 provided at the location of the melting furnace 1 so that the desired pouring status is obtained in response to the output of the pouring status detecting means 4. Is output or controlled.

Further, the display output or control means 8 provided at the place where the molding sand is kneaded is desired by the operation of the processing circuit 10 based on the output of the means 7 for detecting the situation of molding using the molding sand. Output or control the kneading operation of the foundry sand so that the molding situation is achieved.

The memories 11 and 12 are constructed and stored with data, which is accumulated accumulated experience of skilled persons over a long period of time, that is, a knowledge base created based on the knowledge of the expert. The operation is read from the memories 11 and 12, and the operation is performed.

FIG. 2 is a simplified sectional view of the melting furnace 1. In the raw material charging step S1, steel material, return material, metal such as pig iron, and coke, Fe-Si, Fe-Mn, etc. are charged into the charging port 13a. From the tap hole 15 of the furnace body 14 of the melting furnace 1, tapping is performed as indicated by reference numeral 16, and the furnace body 14 has a molten metal 17 and a slag 18 in order from the bottom to the top, and a blower pipe 19 Wind box 2
The air entering 0 is introduced from the tuyere 21 into the furnace body, the bed coke 22 is formed in the furnace body 4, and the metal 2
3 is inserted, and the charging coke 24 is charged. The molten metal discharged from the melting furnace 1 is poured into the mold 2 as indicated by reference numeral 25 in the pouring step S3.

FIG. 3 is a block diagram showing a specific configuration of the processing circuit 10. The accumulated experience of the casting process by the expert is stored in the memories 11 and 12 as described above, and the knowledge base which is the stored contents of the memories 11 and 12 is transferred to the memory 26 of the processing circuit 10 and stored. The stored contents of the memory 26 are used by the inference engine 27 and output to the display output or the control means 5, 6, 8 based on the outputs of the detection means 3, 4, 7.
Further, it is output to the display output means 13 and further displayed by the display output provided by the location of the mold 2 in the pouring step S3 or the control means 28. The key input means 29 inputs the required characteristics of the casting which is the product, and the inference engine 27 operates accordingly. Required characteristics of a product are, for example, the shape of the product,
The desired properties of the material, such as gray cast iron and spheroidal graphite.

FIG. 4 is a block diagram showing the structure relating to each of the steps S1, S2 and S3 more specifically. The means 3 for detecting the operation status of the melting furnace 1 is a chemical component discharged from the tap hole 15, for example, C, Si, Mn, P, S.
Etc., hot water temperature, forced-in coke ratio, bed coke height, and the amount of air blown from the air blower tube 19, air pressure, temperature, etc. are detected, and these detected data are sent to the processing circuit 10 via the interface 9. give. Furthermore, the pouring condition detecting means 4 detects the temperature of the cast iron poured into the mold 2 and supplies it to the processing circuit 10 via the interface 9.

FIG. 5 is a part of a flowchart showing the operation steps of the processing circuit 10 for explaining the operation of the melting step of steps S1 to S3. Moving from step a1 to step a2, the IF section is realized by steps a2 to a4, and it is judged whether there is an abnormality in the molten metal properties, whether the coke ratio is low, and whether the height of the bed coke is low. When the condition is satisfied, the operation proceeds to step a5, which is the THEN section, and it is determined that the shortage of injected coke is the cause. After the cause of such an abnormality in the molten metal property has been clarified, the fact is displayed on the display output or the control means 5 in the raw material charging step S1 before step S2, and is indicated by reference numeral 31 in FIG. As described above, the amount of steel, return material, pig iron, coke, etc., is instructed or controlled.

When an abnormality in the pouring temperature is detected, the processing circuit 10 causes the air output, as indicated by the reference numeral 32 in FIG. 4, by the display output or the control means 6 in step S2 prior to step S3. Instructing or controlling, or instructing or controlling the hot air temperature, if any abnormality of various equipment is inferred, it is displayed and output, and necessary measures are taken. In this way, each display output or control means 5,
By looking at 6 and performing the work according to it, or appropriate measures are automatically taken, and it is possible to prevent defects in the casting process.

In order to detect the charging of raw materials, the detection means 3
3 is provided, which detects the input amount of steel material, return material, pig iron, coke, etc., and displays the detection result in the interface 9
To the processing circuit 10 via. The display output or control means 28 is provided at the location of the mold 2, and displays the pouring temperature detected by the detection means 4 as indicated by the reference numeral 34, and may also display the operation tendency, that is, the trend. It is also possible. Further, the contents displayed by the respective display output or control means 5, 6, 28 and further by the display output or control means 8 are the display output means 1
3 is also displayed and output, and again the printer 1
The display output is printed by 4, and thus the trend of various data is displayed and the abnormal process is displayed.

FIG. 6 is a preparation system diagram of the molding sand kneading step R1 (see FIG. 1 described above). In preparing foundry sand, new sand, old sand, clay and additives are mixed, and water is further added and kneaded.

FIG. 7 is a perspective view of a so-called roller vertical rotation type sand mill which performs the kneading step R1. A main rotary shaft 37, which is driven by a motor 36, is provided in the body 35, and thereby a roller 38 is rotationally driven in the body 35. The pressure device 39 may be omitted. The molding sand is kneaded using such a sand mill.

FIG. 8 is an example of a front view showing the molding step R2 more specifically. In FIG. 8 (1), the flask 4
0 is moved onto the conveyor 41 to be framed. Next, the table-up operation is performed as shown in FIG.
2 is raised, where the foundry sand is fed to the flask 40 as indicated by reference numeral 43 as shown in FIG. 8 (3) to perform the sand pouring and jolt sand break-in work. Then, the head 44 is lowered as shown in FIG. 8 (4), and the molding sand 45 is pressed and squeezed while vibrating the head 44 as shown in FIG. 8 (5). Next Figure 8
In (6), the head 44 is taken out, sand scrubbing and sprue assisting work are performed, and then in FIG. 8 (7), the casting frame 40 is pulled out to start drawing, and at the same time, vibrator vibration is performed. Thus, the mold 2 is manufactured as shown in FIG. The model 42 is cleaned for reuse.

FIG. 9 is a block diagram of a more specific configuration showing the molding sand kneading step R1 and the molding step R2 included in the molding sand treatment step. The means 7 for detecting the molding status detects the temperature, air permeability, compressive strength, that is, coercive pressure, compactability, moisture, etc. of the foundry sand. The output of the detecting means 7 is the interface 9
To the processing circuit 10 so that the processing circuit 10 has a desired molding condition, as indicated by reference numeral 46, on the display output or the control means 8 provided at the place where the molding sand is kneaded. Instructing or controlling the kneading operation of foundry sand, for example, instructing or controlling the amount of various additives or the amount of water added.

FIG. 10 is a part of a flow chart showing an example of a knowledge base by the processing circuit 10 in such a molding sand processing step. The IF section includes step b1 through step b2 and step b5, and the THEN section corresponds to step b6. From step b1 to step b2, the sand temperature at the time of kneading the foundry sand is 46 to 48 ° C., or the water content of the foundry sand at that time is 4.0 at step b3.
Is 4.2% or the temperature is 28 in step b4.
It is determined whether the temperature is ˜30 ° C., or whether the humidity is 60 to 65% in step b5, and when all of these are satisfied, the water input amount is increased in step b6 to instruct the cooling of the foundry sand. The display or control by the display or control means 8 is performed.

Further, in the molding sand kneading step R1,
The detection means 47 is provided and the same detection as that of the above-mentioned detection means 7 is performed.
Given to. The output of such detection means 47 also
It can be used for display output or display or control by the control means 8 or can be displayed by the display output means 48 provided at the molding place of the molding step R2. These contents can also be displayed by the display output means 13 as described above. The display by the display output means 48 is the above-mentioned various information data, as indicated by reference numeral 49, or is also a trend display. The display output of the display output means 13 includes the above-mentioned abnormality in steps R1 and R2.

[0028]

As described above, according to the present invention, a raw material containing a metal is melted in a melting furnace such as a cupola, and the molten metal is poured into a mold based on the knowledge of an expert. Inferences are made based on the knowledge base and the detected data, and more specifically, the operation status of the melting furnace is detected, and also the pouring status of pouring into the mold is detected, and the desired operation Instructing or controlling the charging operation of raw materials including metal, and instructing or controlling the operation of the melting furnace to achieve the desired pouring condition. Upon molding, the molding sand condition was detected, and the kneading operation of the molding sand was instructed to be output or controlled so that the desired molding condition was achieved, so comprehensive management is performed in the casting process. casting It is possible to prevent the occurrence of such a problem, and even if a problem occurs, it becomes possible to take measures without causing a time lag. Since it is possible to output instructions, even if the operator is unfamiliar,
Appropriate casting process operations can be performed, and high quality castings can be manufactured. In this way, it is possible to take appropriate measures before abnormalities such as defects occur, so that casting defects are reduced, and the tendency of each step of the casting process, that is, the trend, is stored and stored in memory. This also makes it possible to utilize it as a reference material when taking countermeasures when a casting defect occurs.

[Brief description of drawings]

FIG. 1 is an overall system diagram of an embodiment of the present invention.

FIG. 2 is a diagram showing a raw material charging step S1, a melting step S2 by the melting furnace 1 which is a cupola, and a pouring step S3 for pouring the molten metal into the mold 2.

3 is a block diagram showing a specific configuration of a processing circuit 10. FIG.

FIG. 4 is a block diagram showing a specific configuration related to a raw material charging step S1, a melting step S2, and a pouring step S3.

FIG. 5 is a flowchart showing an example of an operation in a melting step of the processing circuit 10.

FIG. 6 is a flowchart showing the casting sand kneading step R1 more specifically.

FIG. 7 is a perspective view of a sand mill for kneading foundry sand.

FIG. 8 is a diagram for explaining a molding step R2.

FIG. 9 is a block diagram specifically showing a foundry sand kneading step R1 and a molding step R2.

FIG. 10 is a flowchart for explaining the operation of a foundry sand processing step by the processing circuit 10.

[Explanation of symbols]

 1 Melting Furnace 2 Mold 3 Means for Detecting Operational Condition of Melting Furnace 4 4 Means for Detecting Pouring Condition 5, 6, 8, 28 Display Output or Control Means 7 Means for Detecting Molding Condition 9 Interface 10 Processing Circuit 13 , 48 display output means 14 printer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number FI Technical display location G06F 19/00 // F27B 3/28 7727-4K (72) Inventor Norio Tamura Nishi-ku, Kobe City, Hyogo Prefecture Kawasaki Saki Heavy Industries, Ltd. 234 Matsumoto, Higashiya Town (72) Inventor Norio Kurose 234 Matsumoto, Higashiya Town, Nishi-ku, Kobe City, Hyogo Prefecture Kawasaki Heavy Industries Ltd., Nishi Kobe Plant

Claims (3)

[Claims] 1. A work supporting method for a casting process, comprising: charging a raw material containing a metal into a melting furnace; melting the raw material in the melting furnace; and pouring the molten metal into a mold. Based on the step of detecting physical or chemical data in at least one of the melting step and the pouring step, the knowledge base created based on the knowledge of the expert, and the data detected in the detection step Reasoning is performed using a computer, and the state quantity of the raw material charging step or raw material melting step or the step of outputting the work instruction in the raw material charging step or raw material melting step that is performed before that is performed so that the desired casting is performed. And a step of controlling, a work supporting method for a casting process. 2. A method for supporting work in a casting process, comprising the steps of kneading molding sand and molding using molding sand, the step of detecting physical or chemical data in the molding step, and the knowledge of an expert. Based on the knowledge base created on the basis of the data and the data detected in the detection step, inference is performed using a computer, and the work instruction in the casting sand kneading step that is performed before that is performed so that the desired casting is performed. And a step of controlling the state quantity of the casting sand kneading step, the work supporting method of the casting process. 3. A means for detecting the operation status of the melting furnace, a means for detecting the pouring status of pouring the molten metal from the melting furnace into a mold, and a means for detecting the status of molding using molding sand. Indication output or control means provided at the place of charging raw materials including metal, the place of melting furnace, and the place of kneading the foundry, the operation status detecting means, pouring status detecting means, and molding status In response to the output from the detection means, the knowledge base created based on the expert's knowledge is used to make inferences using a computer so that the desired casting is performed, and the raw material containing the metal ingot is placed in the melting furnace. Indication output or control means provided in the melting furnace location to output or control the charging operation of the raw material so that the desired operating condition is achieved by the display output or control means provided in the charging location. To I,
Instructing or controlling the operation of the melting furnace so that the desired pouring condition is achieved, and the kneading work of the foundry sand is performed by the display output or control means provided at the place where the foundry sand is kneaded so that the desired molding condition is achieved. A work support device for a casting process, comprising: means for outputting an instruction or controlling.