KR20230001137A - Method and apparatus for manufacturing throttle body of automobiles by using die casting - Google Patents

Abstract

The present invention relates to a method for manufacturing a throttle body for a vehicle using diecasting. The method includes the following steps of: installing a mold for molding a product in a diecasting device; injecting aluminum alloy molten metal in a state in which the mold is positioned; separating the product after having the molten metal cooled; processing the separated product; and inspecting the processed product. The product includes a first hole part in which a driving module is to be installed, a second hole part positioned opposite the first hole part, and a third hole part for forming an air passage while being at right angles to arrangement directions of the first hole part and the second hole part, wherein the length of the third hole part is greater than the total of all lengths connecting the first hole part with the second hole part. In the step of processing the separated product, the product can be processed by a jig device including a bed arranging and fixing the product in one direction and a rotation driving part rotating and driving the bed. Therefore, the present invention is capable of improving speed by inspecting multiple products at the same time.

Description

Method and apparatus for manufacturing a throttle body for vehicles using die casting {METHOD AND APPARATUS FOR MANUFACTURING THROTTLE BODY OF AUTOMOBILES BY USING DIE CASTING}

The present invention relates to a method and apparatus for manufacturing a throttle body for a vehicle using die casting.

A throttle valve in an automobile is located between an air filter and an intake manifold and serves to control the amount of inflow air into the engine. The driver can adjust the amount of air sucked into the engine by controlling the throttle valve according to the will to accelerate.

The throttle body, as a body constituting the throttle valve, supports the parts and maintains airtightness. Since it is used at a temperature of 100 ℃ or higher and is subjected to repeated vibration loads, high-temperature strength and fatigue strength are required.

Aluminum alloys are attracting the most attention as alternative materials for weight reduction of automobiles. By adding various materials such as silicon (Si), zinc (Zn), and magnesium (Mg) to the aluminum base, it is possible to secure high specific strength, excellent high-temperature hardness and strength, and corrosion resistance and wear resistance. Applications are expanding to parts, compressors, oil pumps, and fork shifts.

Die casting is a representative metal processing method that can be manufactured from such an aluminum alloy material. However, die casting has the characteristic of being able to produce a product from molten metal in a short time, but it is fundamentally difficult to completely control casting defects due to shrinkage and bubbles, so there are limitations in application to parts requiring pressure resistance and high strength.

In order to control casting defects while maintaining the high productivity of the general die casting method, a vacuum die casting method and a local pressure die casting method are sometimes applied.

Efforts to reduce global warming and carbon dioxide emissions are also affecting the improvement of throttle bodies. For example, the throttle body is relatively thin even though the length is about twice as long compared to the existing product. In this case, the length of the slide core is also increased due to the characteristics of the shape. At this time, there is also a risk of occurrence of seizure by the core and consequent leakage. In addition, it is difficult to secure the dimensions of the inner diameter only by die-casting in the section other than the operating section of the throttle valve.

*Related prior art

Korean Patent Publication No. 10-2021-0011587 (published on February 2, 2021)

Korean Patent Publication No. 10-2008-0111651 (published on December 24, 2008)

One object related to the present invention is a manufacturing method of a throttle body using die casting capable of minimizing the possibility of sticking by a slide core and consequent leakage and minimizing deformation of the slide core in manufacturing a longer throttle body by die casting, and a method for manufacturing a throttle body using the same It is to present a throttle body manufactured by

Another object related to the present invention is to secure a stable reference surface through die casting and obtain stable precision dimensions while preventing the processing surface from changing through this.

Another object related to the present invention is to increase the dimensional precision of a cast product and improve the reliability and speed of inspection.

Another object related to the present invention is to provide a die-casting manufacturing method of a throttle body and a throttle body manufactured by the method capable of minimizing restrictions on the arrangement space of a drive unit caused by arranging a slide core and improving mass productivity.

A method of manufacturing a throttle body for a vehicle using die casting related to the present invention includes installing a mold for forming a product in a die casting device; injecting molten aluminum alloy in a state where the mold is positioned; Separating the product after the molten metal is cooled; processing the separated product; and inspecting the processed product, wherein the product includes a first hole for installing a driving module, a second hole positioned opposite the first hole, and the first hole and the second hole. It has a third hole for forming an air passage perpendicular to the arrangement direction of the hole, the length of the third hole is greater than the sum of the total lengths connecting the first hole and the second hole, and the separation The step of processing the product may be to process the product by a jig device including a bed capable of arranging and fixing the product in one direction and a rotation drive unit for rotationally driving the bed.

As an example related to the present invention, the jig device includes a first jig formed to be able to fix a product corresponding to the first hole portion and detachable from the bed, and corresponding to the third hole portion to fix the product The step of processing the separated product includes: processing the product by the first jig; and processing the product by the second jig.

As an example related to the present invention, the step of inspecting the processed product may include blocking the first hole to the third hole of the product by a leak test device and inspecting watertightness.

As an example related to the present invention, the leak test device includes: a first interface formed so that the first hole can be aligned and put on; a second interface formed to fit the second hole and to be transported by a pressure cylinder; and a pair of third interfaces formed to be in contact with both ends of the third hole and pressurized at both ends of the third hole by a pressure cylinder.

As an example related to the present invention, the mold includes a first mold having a cavity for molding the product; first slide cores, second slide cores, and third slide cores respectively corresponding to the first hole part, the second hole part, and the third hole part of the product; and a second mold facing the first mold.

As an example related to the present invention, at least one of the first slide core to the third slide core may further include a refrigerant circulation type cooler to enable partial cooling.

An apparatus for manufacturing a throttle body for a vehicle using the present invention and die casting includes a mold for forming a product; a molten metal injection unit for injecting molten aluminum alloy in a state where the mold is positioned; a separator separating the product after the molten metal is cooled; a processing unit for processing the separated product; and an inspection unit for inspecting the processed product, wherein the product includes a first hole for installing a driving module, a second hole located on the opposite side of the first hole, and the first hole and the second hole. It has a third hole for forming an air passage perpendicular to the arrangement direction of the hole, the length of the third hole is greater than the sum of the total lengths connecting the first hole and the second hole, The unit may include a bed capable of arranging and fixing products in one direction, and a jig device including a rotary drive unit for rotationally driving the bed.

As an example related to the present invention, the jig device includes a first jig formed to be able to fix a product corresponding to the first hole portion and detachable from the bed, and corresponding to the third hole portion to fix the product It is formed and may include a second jig detachable to the bed.

As an example related to the present invention, the inspection unit includes a leak test device configured to block the first hole portion to the third hole portion of the product and inspect watertightness, and the leak test device includes the first hole portion A first interface formed to be fitted and placed on top of each other; a second interface formed to fit the second hole and to be transported by a pressure cylinder; and a pair of third interfaces formed to be in contact with both ends of the third hole and pressurized at both ends of the third hole by a pressure cylinder.

The present invention also discloses a throttle body for a vehicle manufactured by the above method.

According to the method of manufacturing a throttle body for a vehicle using die casting related to the present invention, the length of the third hole for forming an air passage is relatively long compared to the first hole and the second hole for installing the driving module. It is possible to obtain a stable reference surface through die casting, and through this, stable precision dimensions can be obtained while preventing the processing surface from changing.

According to an example related to the present invention, reliability of a throttle body inspection can be improved through a dedicated leak test device having a first to third interface, and speed can be improved by performing inspections of a plurality of products at once. can

According to another example related to the present invention, while minimizing the generation of air bubbles in the first hole and the second hole, it is possible to secure the dimension of the third hole without processing the inner diameter even though the thickness is thin. As a result, it is possible to secure mass productivity while satisfying the quality demanded by the customer. In addition, by applying 2 cavities to one mold and utilizing 6 slide cores, it is possible to precisely control molten metal and temperature along with the required shape.

1 and 2 are perspective views of a throttle body for a vehicle related to the present invention.
3 is a flowchart illustrating a method of manufacturing a throttle body for a vehicle using die casting with improved productivity related to the present invention.
4 and 5 are molten metal modeling drawings for two-cavity die-casting of the throttle body in relation to the present invention.
6 are initial flow analysis images for 2-cavity die-casting of a throttle body in relation to the present invention.
7 and 8 are perspective views showing a molding apparatus for a throttle body for a two-cavity vehicle using die casting related to the present invention.
9 is a photograph showing a state in which a refrigerant circulation type cooler is disposed in order to minimize seizure of the slide core.
10 are cross-sectional images for observing the air quality of a product cast by a method of manufacturing a throttle body for a vehicle using die casting with improved productivity related to the present invention.
11 and 12 show a jig device capable of improving dimensional accuracy for a die-casting product in relation to the present invention.
13 to 15 show a leak test device capable of inspecting the pressure resistance characteristics of a processed product in relation to the present invention.

Hereinafter, a method and apparatus for manufacturing a throttle body for a vehicle using die casting related to the present invention will be described in detail with reference to the accompanying drawings.

As shown in FIGS. 1 and 2 , the throttle body 10 for a vehicle related to the present invention includes shape elements capable of implementing functions for combining and supporting parts. Looking at these shape elements from the viewpoint of manufacturing for die casting, the first hole 20 for installing the driving module (referring to a motor and gear) and the second hole 30 located on the opposite side of the first hole 20 ) and a third hole 40 for forming an air passage. The first hole part 20 and the second hole part 30 are parts where the shaft of the valve blade rotated by the gear and an element for sensing the rotation angle are coupled. Therefore, the first hole part 20 and the second hole part 30 are aligned in a straight line, and the third hole part 40 forms a right angle to the arrangement direction of the first hole part 20 and the second hole part 30. .

As shown in FIG. 2 , the length L1 of the third hole 40 is larger than the sum L2 of the total lengths connecting the first hole 20 and the second hole 30 . For example, the vehicle throttle body 10 of this example has a narrow and long structure with a length of about 100 mm and a thickness of 2.5 mm, and is more than twice as long as existing products. When it is manufactured by die casting, not only the slide core for forming the third hole portion 40, but also the length increases when the first hole portion 20 and the third hole portion 40 are formed by the slide core. There is room for seizure problems that occur in

One side of the third hole 40 may also include an outer diameter increasing portion 41 having a relatively increased outer diameter and a groove portion 42 for installing an O-ring on the outer diameter increasing portion 41 . In this case, air bubbles around the grooved portion 42 and securing molding quality may be problematic. This will be described in detail later.

As shown in FIG. 3, in order to manufacture the throttle body 10 for a vehicle related to the present invention by die casting, a design analysis step for manufacturing a mold (S10), a step for arranging a completed mold (S20 to S30), and molten metal Managing and injecting (S50), separating the product (S60), processing the cast product into the required shape or surface (S70), and inspecting the product for quality control (S80), etc. Elemental technologies of can be included.

In the design analysis step (S10), flow and solidification situations are analyzed, and a cooling channel and an optimized mold are designed accordingly. In relation to the present invention, a mold design capable of increasing mass productivity was applied while the tonnage was large (350 tons, 650 tons, etc.).

As shown in FIGS. 4 and 5 , an example configured to simultaneously cast two products 110 and 120 by a common molten metal injection unit 101 is presented. The first product 110 and the second product 120 are arranged to face each other with the common molten metal injection unit 101 as the center. At this time, the first product 110 is the first hole portion 20 so that the first hole portion 20, the second hole portion 30, and the third hole portion 40 of the product described above can be molded into a desired shape and quality. ), and includes a first slide core (C1), a second slide core (C2) and a third slide core (C3) for forming the second hole portion 30 and the third hole portion 40, the second product Similarly, 120 also includes a fourth slide core C4, an ostand portion 111, and a sixth slide core C6 for forming the first hole portion 20, the second hole portion 30, and the third hole portion 40. ) is configured to have. The third slide core (C3) and the sixth slide core (C6) are arranged in a straight line, and the first slide core (C1) and the second slide core (C1) and The two slide cores C2, the fourth slide core C4, and the fifth slide core C5 are each arranged in a straight line.

The first slide core (C1) and the fourth slide core (C4) are different in size from the second slide core (C2) and the fifth slide core (C5), and to reduce the space restriction accordingly, the second product ( 120) can achieve an asymmetric arrangement rotated by 180 degrees with respect to the first product 110 around a straight line virtually connecting the third slide core C3 and the sixth slide core C6.

A ring gate 104 may be included so that molten metal can be evenly guided from the common molten metal injection unit 101 to the third hole 40 . At this time, it is also possible that the ring gate 104 is formed to be open on one side.

Vacuum runners 105 and 106 may be formed to reduce casting defects and improve molten metal flow, and overflow parts 107 and 108 may be disposed at appropriate locations to improve bubble defects and filling performance. . In particular, by installing the overflow part adjacent to the groove-shaped part 42, the air pressure problem can be remarkably improved. In addition, in order to improve the flow in the grooved portion 42, an additional connection gate 103 branched from the common molten metal injection portion 101 and connected to an adjacent portion of the grooved portion 42 is installed.

6 shows the flow analysis process for the initial shape in consideration of these matters. That is, as shown in (a), the temperature distribution during charging can be predicted according to the position of each part, and the change in temperature between the lowest temperature part of 630 degrees and the liquidus line can be confirmed, and the charging pores are different due to the asymmetric arrangement of the left and right can see

(b) shows the state of the molten metal according to the injection speed distribution. That is, it was measured at 854 ms, when the high-speed conversion was completed. Although the gate speed is relatively low at about 20 to 25 m/s, there is no problem with charging because it is a thick product. At this time, a slow gate speed can reduce air inflow into the product and prevent mold erosion as long as there is no problem with filling.

(c) shows a high pressure distribution on the face of the assembly part and the like. High pressure parts can cause unfilled or blisters. In this case, a vacuum can preferably be applied.

(d) shows air entrapment, (e) is a hot spot, and (f) is a predicted shrinkage defect, respectively. That is, since the holding pressure occurs for a relatively long time, the location of the shrinkage defect in the product may be different, and it is desirable to manage the defect accordingly.

7 and 8 show a molding apparatus for a throttle body for a two-cavity vehicle to which a modified shape or design is applied based on this analysis.

As shown in these figures, the first mold 201 and the second mold 202 include respective cavities for molding each product on the left and right from the molten metal injection unit 201, and the first mold 201 and the second mold 201 Around the mold 202, a drive device 231 for the first slide core C1, a drive device 232 for the second slide core C2, and a drive device 233 for the third slide core C3 ), a drive device 241 for the fourth slide core C4, a drive device 242 for the fifth slide core C5, and a drive device 243 for the sixth slide core C6 are installed. . The vacuum units 251 and 252 are disposed at the corners to minimize spatial interference with the first slide core C1 to the sixth slide core C6.

As the length of the product increases to about 100 mm with respect to the third hole 40 of the product compared to existing products, the length of the slide core also increases to about 200 mm. Therefore, the risk of deformation of the core pin may increase when a burr is generated in the parting portion. In addition, since the repeated load received by the core pin increases as the high-speed and high-pressure casting method is used, a titanium (Ti) coating layer can be applied to the slide core as a structural alternative to this.

9 shows a state in which a refrigerant circulation type cooler is disposed in order to minimize seizure of the slide core. That is, the nozzles 310 and 330 are installed directly to inject the release agent and air into the mold to minimize the deformation of the slide core and the seizure on the surface in a high-temperature and high-pressure environment even though the length is long according to the characteristics of the product. there is. At this time, the nozzle 310 may include a ball 320 to adjust the injection position.

10 are cross-sectional images for observing the air quality of a product cast by a method of manufacturing a throttle body for a vehicle using die casting with improved productivity related to the present invention. According to this example, as in (a), the cast product was cut into four positions and the surface was observed (b, c, d, e). All of these show that there are almost no air bubbles in the product compared to the results cast by the conventional method, and through this, it can be confirmed that the casting quality can be secured while improving mass productivity.

11 and 12 show a jig device capable of improving the dimensional accuracy of a die-casting product in relation to the present invention.

Applying a 3- or 4-side slide and applying a top/bottom product design to all 6 sides of the moving section, and when setting for processing, the position of the reference plane is different for each lot, which can cause changes accordingly, so apply the reference plane to minimize this. It is necessary to establish a stable processing method through For example, in the OP10 process, it is preferable to make a stable reference surface when switching to the OP20 process by setting and manufacturing a jig based on the most stable surface among unstable slide surfaces. Through this, it is possible to obtain the satisfaction of the machining dimensions of the upper and lower assembly surfaces of the valve operating section, which requires dimension management. To this end, as shown in FIGS. 11 and 12, the jig device may include a bed 410 capable of fixing the product 10 in one direction and a rotation drive unit 420 for rotationally driving the bed 410. . The jig device also includes a first jig 430 that is formed to fix the product corresponding to the first hole 20 and is detachable from the bed 410, and corresponding to the third hole 40 to fix the product. It is formed to be able to include a second jig 440 detachable from the bed 410. Through this, it is possible to set based on the bottom surface of the rib-shaped part processed in the OP10 process. When assembling the engine, CNC can be used for the upper processing part connected to the intake or exhaust valve pipe, but stable clamping while avoiding the processing part to apply processing to the MCT OP20 process for continuous processing of stable quality such as concentricity and cylindricity. this is possible

On the other hand, in the case of the valve assembly section associated with the first hole 20 of the inner part of the product, it is the most important part. Even if one processing part is slightly wrong, the opening and closing of the valve is not matched, so product performance cannot be satisfied. It is possible to secure stable precision dimensions by designing the jig so that the same processing is possible through the application of index equipment based on the lower processing surface for the same processing application of the top and bottom.

13 to 15 show a leak test device capable of inspecting the pressure resistance characteristics of a processed product in relation to the present invention.

The contents of the inspection performed in the inspection step (S80) may vary. Inspection of the pressure resistance characteristics of the double die-casting completed product 10 is very important, and in this example, a leak test device capable of inspecting this exclusively will be described.

The leak test device includes a housing 601 capable of testing a plurality of products 10 at once or sequentially. In the housing 601, the first interface 610 formed so that the first hole 20 can be aligned and placed on it, and the second hole 30 is formed so that they can be aligned and transported by the pressure cylinder. A pair of third interfaces 640 formed to be in contact with both ends of the second interface 630 and the third hole portion 40 and pressurized both ends of the third hole portion 40 by a pressure cylinder ) may be included. In addition, a sealing unit 620 capable of blocking an opening formed on one side of the product 10 is provided.

14, when the product 10 is supplied while being placed on the first interface 610, the pressure cylinder of the second interface 630 and the pressure cylinder of the third interface 640 operate respectively to automatically The inner space of (10) is sealed, and in this state, air pressure is supplied to the inside and leakage of pressure is measured (FIG. 15). Reliability of the throttle body inspection can be improved through this dedicated leak test device, and speed can be improved by performing inspections of a plurality of products at once.

The method and apparatus for manufacturing a throttle body for a vehicle using die casting described above are not limited to the configurations and methods of the described embodiments. The above embodiments may be configured by selectively combining all or part of each embodiment so that various modifications can be made.

10: vehicle throttle body 20: first hole
30: second hole part 40: fourth hole part
41: outer diameter increasing shape portion 42: groove shape portion
101: molten metal injection unit 102: Jugate
103: additional connection gate 104: ring gate
410: bed 420: rotary drive unit
430: first jig 440: second jig
610: first interface 620: sealing unit
630: second interface 640: third interface

Claims (10)

Installing a mold for molding a product in a die casting device;
injecting molten aluminum alloy in a state where the mold is positioned;
Separating the product after the molten metal is cooled;
processing the separated product; and
Including inspecting the processed product,
said product,
A first hole for installing a driving module, a second hole located on the opposite side of the first hole, and a third hole for forming an air passage perpendicular to the arrangement direction of the first hole and the second hole. have a widow,
The length of the third hole is greater than the sum of the total lengths connecting the first hole and the second hole,
The step of processing the separated product,
A method of manufacturing a throttle body for a vehicle using die casting, wherein the product is processed by a jig device including a bed capable of arranging and fixing the product in one direction and a rotation driving unit for rotationally driving the bed.
According to claim 1,
The jig device,
A first jig formed to be able to fix the product corresponding to the first hole portion and detachable from the bed, and a second jig formed to be able to fix the product corresponding to the third hole portion and detachable from the bed do,
The step of processing the separated product,
processing the product by the first jig; and
A method of manufacturing a throttle body for a vehicle using die casting, comprising processing the product by the second jig.
According to claim 1,
The step of inspecting the processed product,
A method of manufacturing a throttle body for a vehicle using die casting, comprising the step of blocking the first hole part to the third hole part of the product by a leak test device and inspecting watertightness.
According to claim 3,
The leak test device,
a first interface formed so that the first hole can be aligned and put on;
a second interface formed to fit the second hole and to be transported by a pressure cylinder; and
Manufacture of a throttle body for a vehicle using die casting, including a pair of third interfaces formed to be in contact with both ends of the third hole portion and formed to press both ends of the third hole portion by a pressure cylinder method.
According to claim 1,
The mold,
a first mold having a cavity for molding the product;
first slide cores, second slide cores, and third slide cores respectively corresponding to the first hole part, the second hole part, and the third hole part of the product; and
A method of manufacturing a throttle body for a vehicle using die casting, comprising a second mold facing the first mold.
According to claim 5,
A method of manufacturing a throttle body for a vehicle using die casting with improved productivity, wherein at least one of the first slide core to the third slide core further includes a refrigerant circulation type cooler to enable partial cooling.
molds for shaping products;
a molten metal injection unit for injecting molten aluminum alloy in a state where the mold is positioned;
a separator separating the product after the molten metal is cooled;
a processing unit for processing the separated product; and
Including an inspection unit for inspecting the processed product,
said product,
A first hole for installing a driving module, a second hole located on the opposite side of the first hole, and a third hole for forming an air passage perpendicular to the arrangement direction of the first hole and the second hole. have a widow,
The length of the third hole is greater than the sum of the total lengths connecting the first hole and the second hole,
The processing part,
An apparatus for manufacturing a throttle body for a vehicle using die casting, comprising a jig device including a bed capable of arranging and fixing products in one direction and a rotation drive unit for rotationally driving the bed.
According to claim 7,
The jig device includes a first jig formed to be able to fix a product corresponding to the first hole portion and detachable from the bed, and a first jig corresponding to the third hole portion to be able to fix the product and detachable from the bed An apparatus for manufacturing a throttle body for a vehicle using die casting, including a second jig.
According to claim 7,
The inspection unit includes a leak test device configured to block the first hole part to the third hole part of the product and inspect watertightness,
The leak test device,
a first interface formed so that the first hole can be aligned and put on;
a second interface formed to fit the second hole and to be transported by a pressure cylinder; and
Manufacture of a throttle body for a vehicle using die casting, including a pair of third interfaces formed to be in contact with both ends of the third hole portion and formed to press both ends of the third hole portion by a pressure cylinder Device.
A throttle body for a vehicle manufactured by the method of any one of claims 1 to 6.

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