KR102043690B1 - Manufacturing method of die casting castings - Google Patents

Abstract

The present invention relates to a method for manufacturing a die-casting casting, characterized in that the process, the molding process for melting the alloy corresponding to the casting and injecting the molten alloy melt into a mold to produce a casting; A trimming step of dipping the cast product in a bathtub to cool the cut product and cutting unnecessary portions of the cooled cast product; A deburring process of fixing the casting with a clamp and removing burrs of the fixed casting; An inspection process of photographing the cast product with a camera and analyzing a photographed image to determine a defect; And a loading step of transporting the casting and screening defects and sequentially loading the selected casting.
Accordingly, the present invention has the effect of efficiently processing the processes from forming, cooling, and transporting the casting to trimming, deburring, inspection, and loading, thereby improving overall quality and reducing manpower.

Description

Manufacturing method of die casting castings

The present invention relates to a method for manufacturing a die-casting casting, and more particularly, to efficiently process the process from forming, cooling, and transporting to casting, deburring, inspection, and loading, thereby improving overall quality and delivering air. The present invention relates to a method of manufacturing a die casting casting that can be saved.

Typically, a workpiece such as an engine or a transmission that requires precision machining is formed by die casting casting. For example, the oil pump of the automatic transmission is mounted between the torque converter and the transmission housing, and the oil pump receives the engine output through the torque converter, sucks oil accumulated in the oil pan, and flows the oil to the transmission unit to shift the gear. It is responsible for the generation of pressure, lubrication of the transmission, and cooling.

That is, in the transmission, the oil pump supplies the operating oil pressure of the torque converter and the hydraulic control mechanism, and supplies the lubricating oil pressure to the friction parts such as the planetary gear set, the input shaft, and the friction elements of each shift stage. It is an indispensable part, and in particular, the oil passage for sucking and discharging oil is a component that requires a great deal of precision for the smooth supply of oil.

In addition, the valve body, which is a perforated part of a plurality of oil passages mounted on an automobile engine and a transmission's transmission, is a passage that accurately transmits the position of a gear, not simply an oil passage, and provides hydraulic pressure to each hydraulically operated friction element. A flow path is formed, an orifice through which hydraulic pressure is discharged after the operation of the hydraulically operated friction element is formed, and a plurality of hydraulic control valves for opening and closing the respective flow paths are installed.

The valve body should smoothly transmit the hydraulic pressure of various clutches by opening and closing by the valve body solenoid controlled by the computer.In this case, when the valve body does not play a normal role, shock or slip occurs during shifting, which greatly affects fuel efficiency. Get mad.

Looking at the manufacturing process of such an oil pump or valve body, the molding and cooling of the casting, followed by trimming, deburring, inspection process. In other words, in the past, by performing such a process manually, there was a problem that the waste rate of the overall airlift, as well as the failure rate increases.

Recently, as a way to solve this problem, Korean Patent Publication No. 10-2009-0050611 (Invention: Automated apparatus for casting process and control method for valve body) and Korean Patent Publication No. 10-1188816 ( Name of the invention: oil pump cover automatic manufacturing apparatus for an automatic transmission. The proposed literature differs slightly depending on the casting, but it is possible to automatically perform a series of whole processes for manufacturing valve body or pump cover.

However, as the units performing each process are limited to a specific product, they cannot cope with various kinds of castings, and there is a problem that additional work is still dependent on manual work in addition to the process. That is, in the case of the deburring unit, it cannot be replaced with a tool that can cope with the shape of the casting, and in the case of the trimming unit, there is a problem of wasting the overall labor by discharging the remaining parts (scraps) manually.

Republic of Korea Patent Application Publication No. 10-2009-0050611 (Invention: Automated apparatus for casting process for valve body and its control method) Republic of Korea Patent Publication No. 10-1188816 (Invention name: Oil pump cover automation manufacturing apparatus for automatic transmission)

Accordingly, the present invention is to fundamentally solve the conventional problems as described above, and the overall quality is improved by efficiently processing the processes from forming, cooling, and transporting the casting to trimming, deburring, inspection, and loading. The purpose of the present invention is to provide a method of manufacturing a die cast casting that can reduce the man-hours, as well as deburring to cope with various castings, and to recycle the scrap generated after trimming.

In order to achieve the above object, the present invention provides a method for manufacturing a die-casting casting: a molding process for melting the alloy corresponding to the cast, and injecting the molten alloy melt into a mold to produce a cast; A trimming step of dipping the cast product in a bathtub to cool and cutting unnecessary portions of the cooled cast product; A deburring process of fixing the casting with a clamp and removing burrs of the fixed casting; An inspection process of photographing the cast product with a camera and analyzing a photographed image to determine a defect; And a loading step of transferring the casting and screening defects and sequentially loading the selected casting.

At this time, the molding process according to the invention is characterized in that the alloy corresponding to the cast product is prepared, the prepared alloy is dissolved at 680 ~ 750 ℃, the molten alloy melt is injected into the mold at 75MPa.

In addition, the trimming process according to the present invention immerses and cools the castings in a bath where cooling water is circulated, dehydrates the cooled castings by centrifugal force, cuts gates and overflows that are unnecessary portions of the dehydrated castings, and cuts the cut portions. It characterized in that the process of melting.

In addition, in the deburring process according to the present invention, the articulated fixed robot clamps the cast product, the articulated deburring robot removes the burr on one side of the fixed cast, the fixed robot inverts the cast product, and the inverted cast product. Deburring robot is characterized in that the process of removing the burr on the other side.

In addition, in the inspection process according to the present invention, the articulated inspection robot photographs the appearance of the cast product, detects an edge of the captured image, and firstly differentiates the detected edge brightness to determine the position of the inflection point. It is characterized in that the process of determining the failure with a Roberts mask to detect.

Meanwhile, the terms or words used in the present specification and claims are not to be construed as being limited to the ordinary or dictionary meanings, and the inventors should explain the concept of terms in order to explain their own invention in the best way. It should be interpreted as meanings and concepts corresponding to the technical idea of the present invention based on the principle that it can be properly defined. Therefore, the embodiments described in the present specification and the configuration shown in the drawings are only the most preferred embodiments of the present invention, and do not represent all of the technical ideas of the present invention, and various alternatives may be substituted at the time of the present application. It should be understood that there may be equivalents and variations.

As described in the above configuration and operation, the present invention not only efficiently processes the entire process from forming, cooling, and transporting the casting to trimming, deburring, inspecting, and loading, but also deburring to cope with various castings. Together, the scrap generated after trimming can be recycled to improve overall quality and reduce man-hours.

1 is a flow chart showing the manufacturing method according to the invention as a whole.
2 is a plan view showing a die casting automation apparatus according to an embodiment.
3 is a plan view showing the molding machine and the cooler according to FIG.
4 is a configuration diagram showing a trimmer and a melting furnace according to FIG. 2.
5 is a plan view showing a fixed robot and a deburring robot according to FIG.
6 is a plan view showing a loading robot and a transport conveyor according to FIG.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

The present invention relates to a method for manufacturing a die-casting casting, as shown in Figure 1, the casting process sequentially through the molding step (S10) and trim step (S20), deburring step (S30), inspection step (S40), loading step (S50) It is a die casting method of manufacturing.

In order to implement the manufacturing method of the present invention, a die casting automation apparatus as shown in FIG. 2 may be used. These automated devices are only intended to aid the understanding of the present invention and need not be limited to the illustrated structure.

For example, the automation device is a molding machine 11, a cooler 12, a trimmer 21, a melting furnace 25, a fixed robot 31, a deburring robot 32, an inspection robot 41, a sorting conveyor as shown in FIG. It consists of a 51, a loader 55, a loading robot 61 and a conveying conveyor 65.

Molding machine 11 is composed of a pair of fixed die and a movable die in close contact with each other, as shown in Figure 3, the cavity facing each other is formed with a cavity is injected. That is, when the melt is injected into the cavity while the stationary die and the movable die are in close contact with each other, a cast product corresponding to the shape of the cavity is manufactured while the melt solidifies. And the cooler 12 is composed of a bath in which the coolant is circulated to cool the casting.

Trimmer 21 is a fixed die (21a) to move the left and right along the rail to fix the casting on the main body, as shown in Figure 4, the flow to move up and down to the fixed die (21a) to cut the gate and overflow of the casting It consists of the die 21b. Here, the right side of the main body includes a rotary motor 21c for tilting the fixed die 21a to drop the cut portion, and a chute 21d for discharging the dropped cut portion to the outside.

The melting furnace 25 has a heating furnace insulated as shown in FIG. 4, and a heater for melting the cut portion in the heating furnace. Here, a conveyor is provided between the melting furnace 25 and the trimmer 21 to supply the cut portion to the heating furnace. That is, the cut portion supplied from the trimmer 21 is melted and supplied to the molding machine 11 for recycling.

The fixed robot 31 and the deburring robot 32 are composed of articulated arms of six or more axes as shown in FIG. 5, a clamp 31a for holding a casting on one end of the arm, and a spindle 32a for finishing the casting. Are attached respectively. That is, the fixed robot 31 grips the cast product with the clamp 31a, and the deburring robot 32 approaches the deburring position of the cast product fixed to the clamp 31a and removes burrs.

Inspection robot 41 is composed of a six-arm or more articulated arm (arm), such as a fixed robot 31 and a deburring robot (32), is attached to a camera for photographing the casting on one end of the arm. That is, the camera photographs the transferred casting and analyzes the photographed image to determine a defect.

The remaining sorting conveyor 51 selects the defective casting according to the inspection robot 41 in the process of transferring the casting to the loader 55, and the selected casting is shipped by loading the loader 55 into the tray or pallet sequentially. .

And the loading robot 61 is composed of a six-arm or more articulated arm (arm) such as a fixed robot 31 and a deburring robot 32, as shown in Figure 6, the gripper is attached to one end of the arm. That is, the loading robot 61 takes out the casting manufactured in the molding machine 11, soaks the extracted casting in the cooler 12, cools it, supplies the cooled casting to the trimmer 21, and supplies the trimmed casting. Supply to the conveying conveyor (65). The conveying conveyor 65 delivers the casting to a position adjacent to the fixed robot 31.

Hereinafter, looking at the process of manufacturing a casting using an automated device according to an embodiment are as follows.

First, the molding process S10 dissolves the alloy corresponding to the cast product through the molding machine 11 and injects the melted alloy melt into the mold to produce the cast product. That is, the molding step (S10) is to prepare an alloy corresponding to the cast, to dissolve the prepared alloy at 680 ~ 750 ℃, injecting the molten alloy melt at 75MPa into a mold to produce a cast.

Subsequently, the trim step S20 cools the casting manufactured by the cooler 12, the trimmer 21, and the melting furnace 25 in a bathtub, and cuts unnecessary portions of the cooled casting. That is, the trim step (S20) cools the cast product in a bath of the cooler 12 in which the coolant is circulated, and cools the dehydrated cast product by centrifugal force. And the dehydrated casting is cut by the trimmer 21, the gate and the overflow, which is an unnecessary part, and the cut part is collected and supplied to the melting furnace 25 and undergoes a process of melting.

Here, the melt of the melting furnace 25 is supplied to the molding machine 11 as needed and recycled. Of course, it is preferable to remove impurities by adding and spraying a predetermined component or gas before feeding, and to remove impurities through a filter in the feeding process.

Subsequently, the deburring process (S30) fixes the casting with a clamp and removes the burr of the fixed casting. That is, in the deburring process (S30), the articulated fixed robot (31) fixes the casting, the articulated deburring robot (32) removes the burrs on one surface, and the fixed robot (31) inverts the cast. The deburring robot 32 removes the burrs on the other surface of the inverted casting.

Subsequently, the inspection step S40 photographs the cast product with a camera, and analyzes the photographed image to determine a defect. That is, the inspection process (S40) is the jointed articulation inspection robot 41 photographs the appearance with a camera, detects the edge of the photographed image (Edge), the first derivative of the detected brightness of the edge position of the inflection point Defects are determined with a Roberts mask that detects.

Finally, the loading process (S50) transfers the casting to screen the defects, and sequentially load the selected casting. That is, in the loading process (S50), the sorting conveyor 51 transfers the casted product, sorts out defects, and loads the casted product sorted by the stacker 55 in a tray or pallet in order to complete the shipment.

Hereinafter, looking at the operation process to complete the casting by the die-casting automation device according to an embodiment are as follows.

First, when the molding machine 11 produces a casting, the loading robot 61 grips the casting and takes it out of the molding machine 11. Subsequently, the casting product taken out by the loading robot 61 is cooled by soaking in the cooler 12 for a predetermined time and then supplied to the trimmer 21.

The trimmer 21 then cuts off unnecessary portions of the casting, and then moves it to the original position at which the casting was supplied. And the loading robot 61 gripping the cast again, and then supplies to the conveying conveyor (65). Here, the trimmer 21 discharges the cut portion (scrap) to the outside, and the discharged cut portion is supplied to the melting furnace 25 and immediately melted.

Subsequently, the transfer conveyor 65 transfers the cast product to a position adjacent to the deburring unit 30. Then, the fixed robot 31 grips the casting, and then interlocks with the deburring robot 32 to remove the burr of the casting. If the special shape or surface condition of the deburring part of the casting is different, immediately change the tool to the shape and condition.

Then, the fixed robot 31 delivers the casting to the inspection robot 41, and the inspection robot 41 photographs the casting to determine a defect. The casting is then transferred to the sorting conveyor 51 and the casting is sorted according to the determination, and the sorted normal casting is sequentially loaded on the tray or pallet by the loading machine 55.

It is apparent to those skilled in the art that the present invention is not limited to the described embodiments, and that various modifications and changes can be made without departing from the spirit and scope of the present invention. Therefore, such modifications or variations will have to belong to the claims of the present invention.

S10: forming process S20: trimming process
S30: Deburring Process S40: Inspection Process
S50: loading process
11: molding machine 12: cooler
21: trimmer 25: melting furnace
31: fixed robot 31a: clamp
32: deburring robot 32a: spindle
41: Inspection Robot 51: Screening Conveyor
55: loader 61: loading robot
65: conveying conveyor

Claims (5)

In a method of making a die cast casting:
A molding process of preparing an alloy corresponding to the casting product, dissolving the prepared alloy at 680 to 750 ° C, and injecting the melted alloy melt into the mold at 75 MPa;
A trimming step of immersing and cooling the casting in a bath in which cooling water is circulated, dehydrating the cooled casting by centrifugal force, cutting a gate and an overflow, which are unnecessary portions of the dehydrated casting, and melting the cut portion;
The articulated fixed robot clamps the casting, the articulated deburring robot removes the burr on one side, the fixed robot reverses the cast, and the inverted cast deburring robot removes the burr on the other side. Deburring process;
The articulated inspection robot photographs the casting with the camera, detects the edge of the captured image, and detects the position of the inflection point by first differentiating the brightness of the detected edge. An inspection step of determining; And
And a loading step of transporting the casting and sorting defects, and sequentially loading the selected casting. delete delete delete delete

Images