WO2010125845A1 - 鋳物製品の製造方法及び製造工場 - Google Patents

鋳物製品の製造方法及び製造工場 Download PDF

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Publication number
WO2010125845A1
WO2010125845A1 PCT/JP2010/052680 JP2010052680W WO2010125845A1 WO 2010125845 A1 WO2010125845 A1 WO 2010125845A1 JP 2010052680 W JP2010052680 W JP 2010052680W WO 2010125845 A1 WO2010125845 A1 WO 2010125845A1
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WIPO (PCT)
Prior art keywords
mold
casting
wooden
line
full
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PCT/JP2010/052680
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English (en)
French (fr)
Japanese (ja)
Inventor
伊藤　毅
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アイテックエフエム株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Application filed by アイテックエフエム株式会社 filed Critical アイテックエフエム株式会社
Priority to EP10769545.4A priority Critical patent/EP2455170A4/en
Priority to CN201080032313.5A priority patent/CN102438775B/zh
Priority to JP2011511337A priority patent/JP4939668B2/ja
Publication of WO2010125845A1 publication Critical patent/WO2010125845A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00—Casting plants
    • B22D47/02—Casting plants for both moulding and casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/005—Adjustable, sectional, expandable or flexible patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/04—Pattern plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns

Definitions

  • the present invention is to carry out a method for manufacturing a cast product by selectively performing a full mold method and a wooden mold method in one factory according to the type of the cast product, and to implement the method.
  • the wood mold method used here is the one used for the full mold method.
  • the cavity mold (cavity mold) is a wood mold, metal mold, resin mold, and kneaded sand. This is a general term for a mold method using a shrinkable foamed resin mold or the like using a resin shrinkable material.
  • the non-mass production casting manufacturing method using the organic self-hardening casting method is roughly classified into a full molding method and a wooden mold method.
  • the full mold method is a method in which the extinguished foam model in the mold is cast by replacing it with molten metal while being burned off by pouring, and the wooden mold method has a core placed in a mold composed of an upper mold and a lower mold. This is a method that has been practiced for a long time.
  • the full mold method and the wood mold method have advantages and disadvantages, respectively. That is, in the case of the full mold method, there is no need for a wooden mold or a core, so that it is possible to produce quickly and at a low cost in the case of a single item or a small number of production, there is no need to store the wooden mold or the core,
  • the foam model has good workability, and it is possible to create a foam model using 3D solid data and CAD / CAM. Therefore, it is possible to cast a casting with a complex shape.
  • the full mold method and the wood mold method are fundamentally different casting methods, so of course, conventionally, the casting factory for carrying out the full mold method and the wood mold method The casting factory for carrying out the process was separated, and there was no idea of handling both casting methods in the same factory.
  • JP-A-5-85603 Japanese Patent Laid-Open No. 5-309473 Japanese Patent Laid-Open No. 2001-321928 JP 2003-154438 A JP 2005-111499 A
  • the full mold method and the wood mold method have advantages and disadvantages, respectively, but it is desirable to use the full mold method and the wood mold method depending on the product in order to take advantage of each advantage.
  • the two casting methods have fundamentally different technical ideas, there has conventionally been no concept of selectively performing both casting methods in the same factory.
  • an object of the present invention is to provide a casting product manufacturing method and a manufacturing factory using a self-hardening mold that enables high-efficiency production of casting products.
  • the invention according to claim 1 for solving the above-mentioned problem is to be manufactured by providing a casting line by a full mold method and a casting line by a wooden mold method in a single factory with a common mold making line. Based on the judgment factors including the shape, material, and production lot of the cast product, it is possible to select either the full mold method or the wooden mold method to manufacture the cast product. It is the manufacturing method of the casting product to do.
  • the invention according to claim 2 for solving the above-mentioned problem is that in one factory, either the full mold method or the wooden mold method is used based on the judgment element including the shape, material, and production lot of the casting product to be manufactured.
  • a method for producing a cast product by the selected casting method in the center of the factory, a set line of foam model / wooden pattern, one or more sandbox mixers, and Multi-function manipulator with mold reversal, mold removal, scraping and removal, top and bottom mold cover and other mold making functions, complex multifunctional molding line composed of hanging weir production and setting place, placed in front of the molding line
  • a production space and a storage space for casting materials are arranged on the process side, and a sandbox molding space and a pouring / separation space are arranged on the subsequent process side of the molding line, before the molding line.
  • a casting product manufacturing method is characterized in that a casting product is manufactured by performing mold making used for carrying out the casting method and performing the selected casting method using the casting mold.
  • the invention according to claim 3 for solving the above-mentioned problem is that either one of the full mold method and the wooden mold method is used in one factory based on a judgment element including the shape, material, and production lot of the casting product to be manufactured.
  • a method for producing the cast product by the selected casting method A process for producing a casting material including at least a full mold model, and a casting material including at least a main model and a core used in a wooden mold method, used in the full mold method; A step of storing the casting material used in the full mold method and the casting material used in the wooden mold method in a storage space; A process of selecting a casting method of a full mold method or a wooden mold method based on a judgment element including a shape, a material, and a production lot of a casting product to be manufactured; A step of taking out the casting material used for the casting method selected in the selection step from the storage space; The casting material taken out in the take-out step is a foamed model / wood pattern set line, one or more s
  • the method includes a step of storing the completed mold in a storage space and waiting for a pouring call according to the pouring material and the pouring weight before the step of transporting the completed mold to the pouring space, After the pouring call is received, the finished mold is taken out from the storage space and poured in a predetermined pouring booth, and further, due to the full mold method and the wooden mold method. It consists of adjusting the smoke generation time during pouring.
  • the storage space is a three-dimensional warehouse (multi-stage storage shelf, the same applies hereinafter).
  • the invention according to claim 6 for solving the above-mentioned problem is a foam model common to the full mold method and the wooden pattern method, a set line of the wooden pattern, one or more sandbox mixers, and a light load, Multi-function manipulator with heavy load mold reversal, mold removal, disposal, top and bottom mold cover and other mold making functions, composite multi-function molding line composed of hanging weir production and setting place is placed in the center, said molding line Including a casting line by a full mold method and a casting line by a wooden mold method, and the casting line and wood by the full mold method are based on the judgment elements including the shape, material and production lot of the casting product to be manufactured.
  • This is a casting product manufacturing plant characterized in that the casting line by the mold method can be switched and used.
  • the invention according to claim 7 for solving the above-described problem is based on a judgment method including a shape, material, and production lot of a casting product to be manufactured, which casting method is a full molding method or a wooden method?
  • a factory capable of producing the casting product by selecting and implementing, in the center of the factory, a set line of foam model / wooden pattern, one or more sandbox mixers, and mold reversal, Multi-function manipulator with mold-molding function, disposal mold / die-cut, top / bottom mold cover and other mold-molding functions, hanger weir production and set-up place is placed, and on the previous process side of the molding line,
  • a casting material production space and a storage space are disposed, and a sandbox molding space, a pouring space, and a separating space are disposed on the downstream side of the molding line, and the storage space is disposed.
  • the casting material required for carrying out the casting method selected from the full mold method and the wooden mold method is taken out of the casting material storage space between the molding line and the molding line. And a means for supplying a finished mold produced in the molding line to the pouring space between the molding line and the pouring space. is there.
  • At least a foam model for full mold casting, a scrap mold production site, a wood mold and a core mold for wood casting, a core fabrication site, a foam model for these, 3D warehouse for storing molds, wooden molds, core molds and cores, foam model set grounds and core set grounds are arranged.
  • a three-dimensional warehouse for storing and storing empty frames, unpoured and poured molds is arranged, and each work place is connected by an automatic roller conveyor, carriage or other transport means. Thus, the products or work parts can be transported between each other.
  • the present invention is as described above, and according to the method and the factory according to the present invention, a casting line based on a full mold method and a casting line based on a wooden mold method are provided side by side in the same factory. Based on the judgment elements including the shape, material, and production lot of the casting product to be manufactured, either the full mold method or the wooden mold method can be selected and executed.
  • the method for producing a cast product according to the present invention includes a casting line by a full molding method and a casting line by a wooden mold method, and a shape of the casting product to be manufactured by providing a mold forming line in common in a single factory. Based on the judgment elements including the material and production lot, it is possible to select one of the casting method of the full mold method and the wooden mold method to manufacture the cast product, 1 to 3 are schematic plan views showing an example of layout of a foundry according to the present invention for carrying out this method.
  • a composite multifunctional molding line 1 including a multifunctional manipulator 31 is arranged at the center of the first floor of the factory.
  • foam model / wood mold set, sandbox with mixer, multifunctional manipulator 31 is used to reverse the foam model mold, to remove and remove the mold pattern, and to remove the mold pattern.
  • Work such as work, top and bottom mold covering work, hanging weir production and setting are performed. That is, both the full mold method and the mold production such as a wooden mold are performed on the same composite multifunctional molding line 1.
  • a foam model manufacturing site 2 for full mold casting On one side of the molding line 1, that is, on the previous process side, a foam model manufacturing site 2 for full mold casting, a wooden mold and core manufacturing site 3 for wooden casting, these foam models, wooden molds, A three-dimensional warehouse (multi-stage storage shelf) 4 for storing and storing the child molds and the cores, a foam model / wooden set place 5 and a core set place 6 are arranged.
  • Each work place is connected by a conveying means such as an automatic roller conveyor or a carriage, so that the respective casting materials can be conveyed between each other.
  • the full mold model, the wooden pattern, and the core are transferred from the three-dimensional warehouse 4 to each set place of the molding line 1 by an overhead traveling crane operation by an operator.
  • the foam model manufacturing site 2 for full mold casting and the wooden mold, core mold and core manufacturing site 3 for wooden casting these installation parts are located on the third floor. It is structured (see Fig. 2). For example, on the 3rd floor, foam models, scraps, etc., wooden and core molds are manufactured, and on the 2nd floor, foam models are assembled and maintained, and cores are manufactured. In, foamed molds and cores are produced. Moreover, each coating type drying is performed in the upper storage shelf of the three-dimensional warehouse 4.
  • a sandbox molding place 8 and a metal frame / stool place 9 are arranged, and a pouring place 10, a loosening place 11 and a melting place 12 are provided.
  • the three-dimensional warehouse 13 for storing and storing empty frames, unpoured and poured molds, a large mold pouring waiting area that cannot be stored in the three-dimensional warehouse 13, and after pouring A cooling field 14 is arranged. Between each work place, the mold is transported by an automatic roller conveyor, a carriage or the like.
  • a shot blast casting polishing place 16 through the pre-shot product storage place 15, a shot blast casting polishing place 16, a post-shot product storage place 17, a grinder casting surface finishing place 18, a painting place 19, a shipping place 20 and the like are arranged in the order of the work process.
  • the transportation can be performed between the overhead traveling cranes operated by the operator. Further, the conveyance setting of the metal frame and the surface plate between the metal frame / surface platen 9 and the molding line 1 is performed by the overhead crane operation by the operator.
  • Reference numeral 21 denotes a material bunker disposed adjacent to the melting field 12, where material is carried in, stored, and the like.
  • the operations in each of the above workplaces are comprehensively managed by production management software. That is, first, foam models, wooden molds and cores necessary for the full mold method and the wooden mold method are manufactured in advance in the foam model manufacturing site 2 and the wooden mold and core manufacturing site 3 and stocked in the three-dimensional warehouse 4 respectively. The Then, based on various determination factors including the shape, material, and production lot of the casting product to be manufactured, a selection is made between the full molding method and the wooden mold method.
  • the necessary foamed model, scraped mold, etc. are taken out from the three-dimensional warehouse 4 and transferred to the molding surface plate on the automatic roller conveyor of the composite multifunctional molding line 1 and set. . Then, the necessary metal frame is taken out from the metal frame / surface platen yard 9 and set on the molding surface plate by the overhead traveling crane operation, and then the designated kneaded sand is filled in the metal frame by the continuous mixer.
  • the full mold mold is conveyed to the multi-function manipulator 31, and lifted up and inverted by the multi-function manipulator 31, and then the molding surface plate is returned to the foam model / wood mold setting place 5.
  • a pouring platen is set at the lower part of the mold, and then returned to the sandbox molding place 8 in the molding line 1 again.
  • the upper mold frame extracted from the storage place 9 is set on a mold by a crane operation, and is moved by another mixer or by moving the same mixer, and the upper mold frame is filled with kneaded sand, and molding is performed. Is done. Further, a pouring dam required for the dam weir 25 is manufactured and set to be a completed mold.
  • this finished mold is stored and stored in the three-dimensional warehouse 13 as an unpoured mold, and waits for a pouring call according to the pouring material and pouring weight. Then, in the process of transporting the finished mold to the pouring space, after receiving the pouring call, the corresponding finished mold is taken out from the three-dimensional warehouse 13 and poured in a predetermined pouring booth. , Including taking measures to adjust the smoke generation time during pouring due to the wood mold.
  • the removed scraped mold is returned to the three-dimensional warehouse 4 or is crushed and recovered and melted together with the foamed resin facet generated when the foamed model is manufactured, and recycled and reused by the resin manufacturer.
  • the wood pattern for the upper mold and the lower mold is taken out from the three-dimensional warehouse 4 and sequentially placed on the molding surface plate on the same roller conveyor as in the full mold method.
  • the metal frame is set by a crane operation on the sandbox molding site 8 in the same molding line 1 as in the case of the full mold method, and then filled with kneaded sand by a mixer. Be transported.
  • the upper mold is removed from the upper mold pattern by the lift-up operation of the multi-function manipulator 31, and the upper mold is directly inverted and set on the pouring platen on the other automatic roller conveyor that is waiting. Is done. After that, it is sent to the core set conveyor via the drying furnace 22.
  • the lower mold is cut and coated by the multi-function manipulator 31 and set on the pouring surface plate that is waiting. It is sent onto the child set conveyor and the core is set.
  • the upper mold pattern and the lower mold pattern that have been cut out are returned to the foam model / wooden set place 5 for a while and used for reconstruction, or sent to the pattern storage line and stored in the three-dimensional warehouse 4.
  • the core-set mold that has been waiting on the core set conveyor is sent again to the multi-function manipulator 31 from the upper frame, and the upper frame is lifted up and inverted by the multi-function manipulator 31. Wait in state.
  • the used pouring surface plate is once waited on the standby roller until the next mold arrives, or returned to the metal frame / surface plate standby position by a crane operation.
  • the lower mold is called from the core set conveyor and transported to the multi-function manipulator 31.
  • the upper mold that has been lifted up is lowered to cover the lower mold, and the pouring weir is set. Be transported.
  • the full mold mold and the wooden mold use mold are manufactured by using the completely same molding line 1, mixer and multi-function manipulator 31.
  • each material, mold, sand and other materials are automatically transported at the minimum transport distance except for pouring work, and the heavy load crane is in two places, the multi-function manipulator 31 and the loosening place 11, in the building. It is supposed to be installed together with a part or to be installed independently of the building, and the building structure of the entire foundry is made to be a light load structure. Further, the dust collecting device 24 is installed close to the dust generation field, and the duct distance is kept to a minimum. In addition, a small amount of collected dust is collected in a single silo by a pneumatic transporter and reused as concrete and ceramics secondary materials, or appropriately treated as industrial waste at a predetermined location outside the factory. And then discarded.
  • each operation is executed continuously after a necessary time interval, so that production activities are regular and efficient. Will be done.
  • the above example relates to the case where the maximum dimension in the mold (horizontal x vertical x height) is 4000 x 7000 x 3000, the minimum is 2000 x 4000 x 1350, and the molding capacity is 2 to 4 frames / hour.
  • the maximum dimension in the mold (width ⁇ length ⁇ height) is 2000 ⁇ 3000 ⁇ 3000, and the minimum is 1200 ⁇ 1500 ⁇ 500, and the molding ability is a fully automatic molding system.
  • the maximum frame rate is 15 frames / hour.
  • a composite multifunctional molding line 51 is arranged at the center of the factory, and a solid warehouse 52 for a wooden mold, a foam model, a full mold model and a core / core are arranged on one side thereof.
  • a three-dimensional warehouse 53 for boxes is arranged, and a three-dimensional warehouse 54 for shrinking an empty frame / foamed model and a three-dimensional warehouse 55 for unpoured / poured molds are arranged on the other side.
  • model production sites 56 and 57 are installed for making models of the mold method and the full mold method, modifying the model, and modifying the plan so as to be close to the three-dimensional warehouse 52 for the mold, foam model, and full mold model. Is done.
  • the wooden mold / model manufacturing sites 56 and 57 include a foam cutting site 58, a coating site 59, and a drying field 60, and further includes a wooden / core box manufacturing site 61.
  • a core production place 62 for forming, coating, and punching the core is provided so as to be close to the three-dimensional warehouse 53 for the core / core box.
  • the model production sites 56 and 57 and the core production site 62 are multi-layered as necessary.
  • a casting finishing place 64 an automatic ballasting place 65 and a large floor molding place 66 are provided so as to be close to the empty frame / foaming model shrinking three-dimensional warehouse 54, and a three-dimensional warehouse for unpoured and poured molds.
  • a pouring line 67, a full mold pouring booth 68, and a melting yard 69 are provided so as to be close to 55.
  • the models produced at the model production sites 51 and 52 are set on the molding surface plate, wait in advance at the three-dimensional warehouse 4, and wait for a call from the production plan. Then, upon receiving a call from the production plan, the conveyor 71 automatically supplies it onto the transport carriage of the molding line 51 and conveys it to the empty frame set manipulator 72.
  • the foamed model residual material after the model is manufactured is crushed by an attached foam residual material crusher 73 for recycling, and then sent to a foam material melting / molding machine 74 to be melt-molded and re-formed. Provided for use.
  • an empty frame having an appropriate size is called from the empty frame / foamed model shrink standby warehouse 54, and the called empty frame is set on the model transport surface plate by the empty frame set manipulator 72, and the molding line 51 is formed by the carriage.
  • the empty frame set manipulator 72 is sent to and processed for sand filling, vibrating sand filling and sand leveling.
  • the molds that have been subjected to the cutting, reversing, and coating processes by a plurality of manipulators are further sent to the core setting place 77 after remaining in the drying furnace 76 for a while, where the core production place
  • the core produced in 62 is set.
  • the upper mold and the lower mold are put on the automatic mold receiving device 78 and stored in the three-dimensional warehouse 55 for unpoured and poured molds.
  • the lower mold is molded and cured in the molding line 51 and then inverted by the punching manipulator 81, and is lowered onto the molding surface plate in that state and sent to the molding line 51 again. Then wait.
  • the upper frame that is not filled with sand in the sandbox is set on the lower mold waiting in the molding line 51 by the die-cutting manipulator 81 in that state. Then, sandboxing is performed on the upper frame.
  • the mold that has already been set up and down by the mold manipulator 81 is set on the pouring surface plate without being inverted, and the coating line (manipulator 82 for coating) and the drying line ( It passes through the drying furnace 76) and the automatic mold receiving device 78 as it is, and is stored in the three-dimensional warehouse 55 for unpoured and poured molds.
  • the model separated by the punching manipulator 81 is re-molded, it is sent to the roller conveyor of the manipulator 72 for setting the empty frame by the moving carriage and taken out from the three-dimensional warehouse 54 for waiting for contraction of the empty frame / foamed model.
  • the empty frame is set on the molding surface plate by the empty frame setting manipulator 72, and the model is circulated through the molding line 51 again.
  • the model that is not molded again is returned to the three-dimensional warehouse 4 by the conveyor 71 after the mold removal.
  • the foaming mold shrinkage mold is inverted by the punching manipulator 81, then sent to the conveyor 84 by an automatic carriage, waits for the time required for shrinkage in the empty frame / foamed model shrinkage warehouse 54, and after the model shrinkage,
  • the empty frame / foaming model shrinking three-dimensional warehouse 54 is sent to a coating line by a conveyor 84 and a movable carriage.
  • the contracted model is separated from the mold before the coating process by the operator, pulverized by a model crusher, sent to the resin melting device 74, and recycled after molding.
  • the mold is sent to the three-dimensional warehouse 55 for unpoured and poured molds via the coating line, the drying furnace 76, and the automatic mold receiving device 78 by the action of the coating manipulator 82. Wait until there is a pouring call.
  • the upper frame conveying surface plate after mold matching and the mold conveying surface plate after setting the empty frame are each coated by a conveying carriage from the roller conveyor below the three-dimensional warehouse 55 for unpoured and poured molds. Sent to the line.
  • a hanging weir is set on the upper frame by an operator at the hanging weir / clamp setting place 89, and After the upper and lower molds are clamped, the molten metal that has been sent to the pouring line 67 and melted in the melting yard 69 is poured. Then, after the hanging weir and the clamp are removed by the operator at the hanging weir / clamp removing place 90, the apparatus waits again in the three-dimensional warehouse 55 for unpoured and poured water for a predetermined cooling time.
  • All the generated dust is collected by the respective dust collectors 88 installed in the vicinity, transported to a dust silo by an air transport device, shipped as ceramic materials, industrial waste, etc., and processed. All the models are placed on a molding surface plate, and all the molds after die cutting are placed on a pouring surface plate, and each is conveyed by a roller conveyor. Transport in each three-dimensional warehouse is performed in the same manner.
  • a model factory, a repair site, a core production site, and a molding line are located near a three-dimensional warehouse 52 for a wooden mold, a foam model, and a full mold model.
  • These arrangement positions are selectable positions within the range of the distance that enables the shortest transportation between the three-dimensional warehouses.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Devices For Molds (AREA)
PCT/JP2010/052680 2009-05-01 2010-02-23 鋳物製品の製造方法及び製造工場 WO2010125845A1 (ja)

Priority Applications (3)

Application Number Priority Date Filing Date Title
EP10769545.4A EP2455170A4 (en) 2009-05-01 2010-02-23 PROCESS FOR PRODUCING CAST METALLIC PRODUCTS AND MANUFACTURING PLANT
CN201080032313.5A CN102438775B (zh) 2009-05-01 2010-02-23 铸件制品的制造方法及制造工厂
JP2011511337A JP4939668B2 (ja) 2009-05-01 2010-02-23 鋳物製品の製造方法及び製造工場

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JP2009-112143 2009-05-01
JP2009112143 2009-05-01

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WO2010125845A1 true WO2010125845A1 (ja) 2010-11-04

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EP (1) EP2455170A4 (zh)
JP (1) JP4939668B2 (zh)
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CN106001510A (zh) * 2016-07-30 2016-10-12 临沂天阔铸造有限公司 一种镶铸铸造系统
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