WO2018101061A1

WO2018101061A1 - Information display system for casting facility

Info

Publication number: WO2018101061A1
Application number: PCT/JP2017/041267
Authority: WO
Inventors: 貴弘戸田; 加藤　晃一; 拓真中井
Original assignee: 新東工業株式会社
Priority date: 2016-12-01
Filing date: 2017-11-16
Publication date: 2018-06-07
Also published as: CN109153071A; JP6856077B2; JPWO2018101061A1; TW201832900A

Abstract

Provided is an information display system with which necessary information can be obtained at a location where a worker normally performs work. This information display system (100), which displays information pertaining to multiple devices (10, 30) constituting a casting facility (1), is equipped with: device control PLCs (102) that control at least one device (10) in the casting facility and store information pertaining to the devices; computers (106) having a program for converting information pertaining to the multiple devices and stored in the multiple device control PLCs into screen display data for display on a screen; and display screens (108) that display the information stored in the device control PLCs on the basis of the screen display data obtained with the computer programs. Information pertaining to multiple devices is displayed on one screen so as to enable a worker to understand information about the entire casting facility 1.

Description

Information display system in casting equipment.

The present invention relates to an information display system in a casting facility, and more particularly to an information display system that displays information necessary for an operator and information on a device at a remote position.

The casting is obtained by forming a mold, transporting the mold to a pouring position, and pouring the mold. For this purpose, the casting equipment includes a device that adjusts molding sand, molds a mold, and feeds the mold. There is also a device for receiving hot molten metal melted in a melting furnace into a ladle, transporting the received ladle to a pouring position, and pouring it into a mold at the pouring position. Furthermore, there is an apparatus for cooling the molten metal in the mold and separating the cast product and the mold sand. These apparatuses have different performance required for each casting, and the arrangements of the apparatuses are also different.

For this purpose, each device is designed and manufactured, and each device is equipped with a dedicated PLC. Therefore, the actual situation is that an operator of a casting facility obtains and operates information for each apparatus on a display placed in each apparatus. Therefore, a display device that allows an operator to confirm information of the entire facility at a glance is desired.

For example, Patent Document 1 transmits information from a molding machine, that is, a plurality of sensors that measure data relating to a molding apparatus and a sand property measuring instrument that measures data of kneaded sand that is input to the molding apparatus, to a remote location, A molding related information monitoring system for displaying on a remote unit is disclosed.

Also, Patent Document 2 discloses a display device in which a display screen is installed at a high position of an injection molding apparatus and can be visually recognized from a remote position.

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

In the invention disclosed in Patent Document 2, only the information of one device is displayed, and it is incomplete to display the information of a facility having a plurality of devices such as a casting facility.

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

Japanese Patent No. 3480713 JP 2007-45126 A

In order to solve the above-described problem, the information display system according to the first aspect of the present invention forms a mold M and conveys the mold M to a pouring position P6 as shown in FIGS. 1, 6 and 7, for example. In addition, in the casting facility 1 for pouring the mold M to obtain a casting, the information display system 100 displays information on the plurality of

devices

10 and 30 constituting the casting facility 1, and includes at least one of the casting facilities 1. In order to control the device 10 and display information related to the device control PLC 102 that stores information related to the device 10 and the plurality of

devices

10 and 30, which are stored in the plurality of device control PLCs 102 on the screen. Information stored in the device control PLC 102 and the computer 106 having a program for converting the data into the screen display data of the computer 106. And a display screen 108 for displaying based on the obtained screen display data, operator to be able to grasp the information of the whole casting plant 1, and displays information on a plurality of devices 10 on one screen. If comprised in this way, the operator of the installation which has a some apparatus like a casting installation can acquire the information of a some apparatus from one display apparatus, and can grasp | ascertain the information of the whole casting installation. Here, “the information of the entire casting equipment can be grasped” means that the casting equipment, each unit such as a molding unit, a mold conveying unit, a pouring unit, or a molding machine, a kneading machine, a pouring water This means that it is possible to obtain information necessary for an operator to operate each device such as a machine, a surface treatment device, a dust collector, and a melting furnace and to adjust operating conditions.

In the information display system according to the second aspect of the present invention, in the information display system according to the first aspect, for example, as shown in FIGS. 1 and 6, the device control PLC 102 includes a sensor 12 installed in the device 10. Memorize the information measured by. If comprised in this way, the time series of the measured information will be obtained and time series information can be displayed.

In the information display system according to the third aspect of the present invention, in the information display system according to the first or second aspect, for example, as shown in FIG. 1, information stored in the device control PLC 102 is displayed on the screen. An information storage PLC 104 that converts the information into display information is further provided, and the computer 106 converts the information stored in the information storage PLC 104 into screen display data. If comprised in this way, since it will convert into the data for screen display with a computer based on the information from PLC for information storage converted into the information displayed on a screen, the load of a computer will be reduced and it can display quickly. .

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

In the information display system according to the fifth aspect of the present invention, in the information display system according to any one of the first to fourth aspects, the information displayed on the screen includes casting production information, apparatus operation information, One or more pieces of information are included in the molding sand information and the inspection standard information. If comprised in this way, an operator can obtain information required for operation | movement of a casting installation.

In the information display system according to the sixth aspect of the present invention, in the information display system according to the fifth aspect, the production information of the casting includes the planned production number, the current production number, the achievement rate, the defect rate, the model number, and the product number. One or more pieces of information are included. If comprised in this way, an operator can obtain information required for production of a casting.

In the information display system according to the seventh aspect of the present invention, in the information display system according to the fifth or sixth aspect, the operation information of the apparatus includes the operation status of the casting equipment, the cycle time for molding the mold, and the mold. One or more pieces of information are included in the pouring cycle time. With this configuration, the operator can obtain information necessary for operating a plurality of apparatuses.

In the information display system according to the eighth aspect of the present invention, in the information display system according to any one of the fifth to seventh aspects, the molding sand information includes the molding sand temperature, CB value, moisture, air permeability and One or more pieces of information are included in the compressive strength and the atmospheric temperature. If comprised in this way, the operator can obtain required information about molding sand.

In the information display system according to the ninth aspect of the present invention, in the information display system according to any of the fifth to eighth aspects, the inspection standard information includes a product number, a model number, a lot number, and the model. One or more pieces of information are included in the appearance inspection standard corresponding to the number and the lot number. If comprised in this way, the operator can obtain required information about molding sand.

In the information display system according to the tenth aspect of the present invention, in the information display system according to any one of the first to ninth aspects, a second computer different from the computer is connected to the display screen by a LAN, Information stored in the second computer is displayed on the display screen. If comprised in this way, an operator can obtain from one display apparatus including useful information other than the casting installation from a 2nd computer.

In the information display system according to the eleventh aspect of the present invention, as shown in FIGS. 1, 6, 7, 8, and 12, for example, in the information display system according to any one of the first to tenth aspects. The casting equipment 1 includes a molding unit 10 that molds a mold M from mold sand, a mold transport unit 30 that transports the molded mold M, and a pouring unit that pours the mold M transported by the mold transport unit 30. 70 and a casting equipment management computer 91 for controlling the casting equipment 1. The molding unit 10 includes a molding device 14 that molds the mold M, and a molding unit control device 11 that controls the operation of the molding device 14. The molding unit control device 11 receives the molding plan data from the casting equipment management computer 91, controls the molding device 14 so as to mold the mold M with the molding plan corresponding to the molding plan data, and the mold M which has been molded. A mold serial number is issued to the mold serial number, and molding data relating to the mold M is associated with the mold serial number. The mold conveyance unit 30 includes a conveyance mechanism 38 that conveys the mold M one mold at a time, a mold position detection sensor 39 that detects that the mold M has been conveyed, and a mold conveyance unit control that controls the operation of the mold conveyance unit 30. Device 31. The mold transport unit control device 31 controls the transport mechanism 38 so that the mold M is transported intermittently, and receives the mold serial number of the mold M that has been formed by the molding apparatus 14 and can be transported by the transport mechanism 38. By shifting the mold serial number assigned to the mold position where the mold M stops according to the movement of the mold M detected by the mold position detection sensor 39, the mold serial number of the mold M at the mold position and the mold position is shifted. To correspond. The pouring unit 70 includes a pouring machine 72 that pours molten metal from the pouring ladle L 2 into the mold M, and a pouring unit control device 71 that controls the operation of the pouring machine 72. The pouring unit control device 71 receives the ladle serial number associated with the molten state data of the molten metal in the pouring ladle L2, and receives the mold serial number of the mold M at the pouring position P6 from the mold transport unit control device 31. The pouring machine 72 is controlled so as to perform pouring according to the pouring plan corresponding to the pouring plan data corresponding to the mold serial number, and the ladle serial number of the poured pouring ladle L2 is cast. A display screen showing the mold serial number, the molding data associated with the mold serial number, and the ladle serial number and the molten state data associated with the molten state data. 108.

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

In the information display system according to the twelfth aspect of the present invention, in the information display system according to the eleventh aspect, for example, as shown in FIG. 1, FIG. 6, FIG. 7, and FIG. The apparatus control PLC 102 is also used by the molding unit controller 11, and the apparatus control PLC 102 of the mold transport apparatus 30 that transports the mold M to the pouring position P 6 is also used by the mold transport unit controller 31 to pour the mold M. The device control PLC 102 of the pouring device 72 also serves as the pouring unit control device 71. If comprised in this way, the operator can obtain the required information regarding the molding apparatus which molds a casting_mold | template, the mold conveyance apparatus which conveys a casting_mold | template to a pouring position, and the pouring apparatus which pours into a casting_mold | template.

According to the present invention, an operator of a facility having a plurality of devices such as a casting facility can obtain information on the plurality of devices from one display device. Will be able to obtain information.

This application is based on Japanese Patent Application No. 2016-234182 filed on December 1, 2016 in Japan, the contents of which form part of the present application.
The present invention will also be more fully understood from the following detailed description. However, the detailed description and specific examples are preferred embodiments of the present invention and are described for illustrative purposes only. This is because various changes and modifications will be apparent to those skilled in the art from this detailed description.
The applicant does not intend to contribute any of the described embodiments to the public, and the disclosed modifications and alternatives that may not be included in the scope of the claims are equivalent. It is part of the invention under discussion.
In this specification or in the claims, the use of nouns and similar directives should be interpreted to include both the singular and the plural unless specifically stated otherwise or clearly denied by context. The use of any examples or exemplary terms provided herein (eg, “etc.”) is merely intended to facilitate the description of the invention and is not specifically recited in the claims. As long as it does not limit the scope of the present invention.

FIG. 1 is a system diagram illustrating a connection example of a plurality of information devices. FIG. 2 is a diagram illustrating a configuration example of a screen that displays production information. FIG. 3 is a diagram illustrating a configuration example of a screen that displays operation information. FIG. 4 is a diagram illustrating a configuration example of a screen that displays information about the molding sand. FIG. 5 is a diagram illustrating a configuration example of a screen that displays an appearance inspection standard document. FIG. 6 is a plan view showing the configuration of the casting equipment, and shows the casting equipment that receives the hot water from the furnace with the treatment ladle, replaces it with the pouring ladle, and pours it into the mold formed from the pouring ladle. FIG. 7 is an enlarged view of a portion A in FIG. FIG. 8 is a diagram showing a mold feed pusher for conveying a mold and a sensor for detecting the operation thereof. FIG. 9 is a side view of a hot water receiving cart with an air replacement function. FIG. 10 is a side view of the pouring ladle transport cart. FIG. 11 is a side view of the pouring machine. FIG. 12 is a block diagram illustrating data acquired by each unit of the casting facility and data communication between the units. FIG. 13 is a schematic diagram for explaining how the mold serial numbers are shifted. FIG. 14 is a schematic diagram for explaining molten metal state data associated with the position of the ladle, the ladle sequence number, and the ladle sequence number. FIG. 15 is a flowchart showing the flow of data in the casting facility. FIG. 16 is a plan view showing the configuration of the casting equipment, and shows the casting equipment for receiving the molten metal from the furnace into the pouring ladle and pouring it into the mold formed from the pouring ladle. FIG. 17 is an enlarged view of a portion B in FIG. FIG. 18 is a side view of a pouring ladle transport cart with a lifting function.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same or corresponding devices are denoted by the same reference numerals, and redundant description is omitted. First, with reference to FIG. 1, the information display system 100 which displays the information regarding the some apparatus which comprises the casting installation as embodiment of this invention is demonstrated. In the figure, a plurality of devices constituting the casting equipment are omitted, but reference numeral 102 denotes a device control PLC 102 provided in each device. The device control PLC 102 controls the operation of each device and stores information related to each device. Further, the device control PLC 102 stores information measured by a sensor installed in each device. Here, each device is, for example, a molding device, a kneader, a pouring machine, a surface treatment device, a dust collector, a melting furnace, or the like, or a molding unit, a mold transport unit, and a molten metal transport unit, which will be described later. It may be a pouring unit or the like, and is not limited thereto. In addition, the information regarding each device includes information regarding the specifications of each device, information regarding the operating state of each device, and the like, but is not limited thereto. “Storing information” indicates that information can be acquired and then output, and the stored time may be very small. In addition, the sensors installed in each device include, for example, sand input weight, compression rate, static pressure or squeeze pressure, squeeze time, pressure increase speed, squeeze stroke, mold thickness, molding time, etc. Although it is a sensor (measuring instrument) which measures the molding history data of this, it is not limited to these.

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

The information storage PLC 104 converts the information received from the device control PLC 102 into information to be displayed on the display screen 108. Here, the conversion refers to, for example, collecting information on related devices in one table or graph, or arranging the same type of time series information, but is not limited thereto. The conversion process may be performed by the computer 106 without providing the information storage PLC 104.

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

The display screen 108 displays predetermined information using data converted by the computer 106. The display screen 108 is preferably a large display of, for example, 25 type (25 inches) or more. By displaying information on the large display, it is possible to visually recognize the displayed information even if the operator does not approach the display screen 108.

Fig. 2 shows a display example of production information for the molding machine. In the example of FIG. 2, the planned production number, the production number up to the present, the achievement rate with respect to the planned number, the number of defective products generated, the current production, the next model, the next model model, the model model (pattern No.), the model number, Displays the number of productions to date and the planned number. Production information is not limited to these.

Fig. 3 shows a display example of the operation information of the mold making unit. In the example of FIG. 3, whether there is an abnormality, whether it is in automatic operation, operating status (during sand recovery operation, post-processing operation, mold extrusion waiting, pouring wait, 82PS waiting, pouring machine wait, etc.), line Cycle time and FCMX cycle are displayed. Note that “82 PS waiting” means a state in which the pusher cannot proceed with the pushing process due to the state of the subsequent process in the frame breaking process. The “FCMX cycle” means an operation time of one cycle of a molding machine (for example, “FCMX” manufactured by Shinto Kogyo Co., Ltd.). The operation information is not limited to these.

Fig. 4 shows a display example of mold sand information. In the example of FIG. 4, atmospheric temperature, sand temperature, CB value (compactability), moisture, air permeability, and compressive strength are displayed. “MIE-II” indicates the state of the kneaded sand measured by a compactability control device (for example, “MIE-II” manufactured by Shinto Kogyo Co., Ltd.). The state of the kneaded sand immediately before the molding machine measured by a measuring device (for example, “IDST” manufactured by Shinto Kogyo Co., Ltd.) is shown. The information on the mold sand is not limited to these. An operator of the molding apparatus can confirm the production information of the molding apparatus, the operation information of the mold making unit, and the information of the mold sand shown in FIGS.

Figure 5 shows a display example of the mold appearance inspection standard document. In the example of FIG. 5, the appearance inspection standard document is displayed together with the model number and the lot number. When the appearance inspection standard document cannot be displayed on one screen, it may be displayed on a plurality of pages. The worker who conducts the appearance inspection can confirm the appearance inspection standard document tailored to the product from the place where the worker normally works.

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

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

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

Further, a computer (not shown) other than the device control PLC 102, the information storage PLC 104, and the computer 106 described so far is connected to the display screen 108, for example, useful information other than casting facility information, for example, a casting product. You may enable it to display the criteria regarding.

In this way, by using the information display system 100, workers and managers of equipment having a plurality of devices such as casting equipment can obtain necessary information from a single display device at a place where they are normally working. Work efficiency is greatly improved.

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

The molding unit 10 has a pre-molding sand property measuring instrument 12 for measuring the properties of the molding sand before molding. The molding sand before molding is kneaded by mixing, for example, raw sand or sand discharged from the mold separating device 48 with sand collecting device and adding a binder, an additive, a curing agent, moisture and the like. Sand. The properties of the mold sand greatly affect the quality of the mold, and are therefore measured before molding.

The molding unit 10 includes a molding apparatus 14 that molds a mold from mold sand. In the molding apparatus 14, casting sand is put around a model simulating the shape of a product, and two upper and lower molds are formed for one product. There are two types of molds: a framed mold formed in a mold and a frameless mold without a mold. The molding apparatus 14 includes a measuring instrument (not shown) for measuring molding history data such as sand input weight at molding, compression rate, static pressure or squeeze pressure, squeeze time, pressurization speed, squeeze stroke, mold thickness, molding time, and the like. Have.

The molding unit 10 has a marking device 16 for marking a space formed in a mold by a model, that is, a surface into which a molten metal is poured and solidified into a casting, that is, an inner surface, that can be identified for each space. May be. For example, the marking device 16 may cut a plurality of hole-shaped marks on the surface of the mold space with a jig such as a drill while changing the mutual positional relationship, or mark holes or grooves with a laser or the like. May be. When, for example, a hole is formed on the inner surface of each space of the mold, a protrusion is formed at a position corresponding to the hole on the surface of the cast casting, and it becomes possible to identify each casting. Here, every space of a mold is because a plurality of castings may be made with one mold. That is, one mold has a plurality of spaces. That is, by marking on the surface of each molded casting space, a marking is formed corresponding to each casting obtained. Note that the marking device 16 may be provided in the mold transport unit 30. However, if the mold is imprinted immediately after molding, for example, in the case of a self-hardening sand mold, it can be imprinted before being completely cured, and it is easier to imprint without destroying the mold. In particular, in the case of a frameless mold, marking is performed by the marking apparatus 16 while the mold is in the molding apparatus 14.

The mold transport unit 30 includes a mold rail Rf for cooling the mold M while transporting the mold M and transporting it to the mold spreading device 48 from the molding unit 10 to the pouring unit 70. For example, as shown in FIG. 6, the mold rails Rf are juxtaposed, and the mold M is moved laterally between the rails Rf and is alternately conveyed in the reverse direction by the plurality of rails Rf. Therefore, the mold M after pouring is cooled over time, and the molten metal is solidified before reaching the mold spreading device 48 to become a casting. That is, the conveyance path of the mold conveyance unit 30 is conveyed for pouring from the mold making line 32 for processing the mold molded by the molding apparatus 14 into a finished mold ready for pouring, and the pouring machine 72. The mold transport unit pouring zone 33 is roughly divided into a mold transport unit cooling zone 34 in which the poured mold M is transported and cooled over time.

The mold transport unit 30 has a mold feed pusher 38 as a transport mechanism shown in FIG. 8 at a straight end of the rail Rf. The pusher 38 is a device in which a rod expands and contracts to push a mold, and is, for example, an air cylinder, a hydraulic cylinder, or an electric cylinder. The pusher 38 is a sensor that detects the expansion and contraction of the rod, and includes a mold position detection sensor 39 that detects that the mold M is conveyed. The mold position detection sensor 39 may be a limit switch, a proximity switch, a photoelectric switch, or the like. The pusher 38 preferably has a mold position detection encoder 37 in order to perform synchronous pouring or to correctly detect the pouring position even if the thickness of the mold changes. The pusher 38 pushes the rear end molds arranged on the straight rail Rf by one frame, and intermittently conveys the arranged molds by one frame. It is preferable to install a pusher 38 on the opposite side (front end) of the straight rail Rf so that the rod is contracted as it is pushed at the rear end. If comprised in this way, the mold M of 1 row can be suppressed from both ends also during conveyance, and the mold M is stabilized also during conveyance. When the mold M reaches the front end, it is transferred onto the adjacent rail Rf by the traverser T, and is used as the rear end of the mold line there. The traverser T may also include a mold position detection sensor 39.

The molding line 32 of the mold conveyance unit 30 further has a gas drilling device 40, and a hole for removing gas generated when pouring is poured in the mold. The molding line 32 further includes an upper / lower mold reversing machine 41, for example, reversing the upper mold and the lower mold and directing the mold space upward. The molding line 32 further includes a sand cutter 42 to remove and flatten excess sand on the upper surface of the upper mold and the lower surface of the lower mold. The molding line 32 further includes a gate cutter 43 that opens the gate to the upper mold.

The molding line 32 further includes a surface plate carriage set device 44, and a mold is placed on the surface plate carriage. The molding line 32 further includes a core setter 45 for setting the cores in the upper mold and the lower mold. The molding line 32 further includes an upper mold re-inversion machine 46, which is aligned with the direction in which one mold is formed when the upper mold is inverted and two upper and lower molds are overlapped. The molding line 32 further includes a mold aligning / transferring device 47, and the upper mold and the lower mold are combined to form an upper and lower completed mold ready for pouring. In addition, the arrangement | sequence order of the apparatus from the gas drilling apparatus 40 to the core setter 45 is not restricted above, It can replace suitably.

When the mold is a framed mold, for example, as shown in FIG. 6, the mold transport unit 30 includes a gas drilling device 40, an upper and lower mold reversing machine 41, a sand cutter 42, a gate cutter 43, and a surface plate carriage set device 44. The core setter 45, the upper mold re-inversion machine 46, and the mold alignment / mold transfer apparatus 47 are provided, and the mold M molded by the molding apparatus 14 is processed into upper and lower completed molds ready for pouring. When the mold is a frameless mold, processing such as formation of a vent hole, core setting, and mold matching may be performed by the molding apparatus 14, and in this case, the mold transport unit 30 processes the mold. For example, some or all of the devices 40-47 may not be provided.

The mold conveying unit 30 has a mold separating device 48. In the mold separating device 48, the mold is disassembled to take out the casting, and the casting and sand are separated. The casting is shipped as a product through a subsequent process. The core is also separated. The sand is reused for the mold by removing iron powder, a binder and the like mixed with a sand collecting device (not shown).

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

The molten metal transfer unit 50 replaces the molten metal into the pouring ladle L2, the pouring position P1 where the alloy material is charged into the processing ladle L1 from the alloy material charging unit 60, the hot water receiving position P2 where the molten metal is received from the furnace F, and the molten metal. It has a hot water receiving carriage 52 with an empty replacement function that transports the processing ladle L1 to the empty replacement position P4, and a rail R on which the hot water receiving carriage 52 with an empty replacement function travels. When the alloy material and the molten metal are reacted by wire inoculation, the position where the wire is inoculated becomes the charging position P1. In addition, the description “when an alloy material is introduced” hereinafter is read as “when a wire is inoculated”. The alloy material means Mg, Ce, Ca, Ni, Cr, Cu, Mo, V, Ti, etc. added to the molten metal in order to increase the strength and toughness of cast iron, corrosion resistance, heat resistance, wear resistance, etc. Say. The alloy material includes a graphite spheronizing agent. In addition, an inoculant such as calcium silicon, ferrosilicon, or graphite may be added in the alloy material charging unit 60.

As shown in FIG. 9, the hot water receiving carriage 52 with an air exchange function includes a traveling carriage 520 that travels on the rail R and a traveling motor 522 that causes the traveling carriage 520 to travel. The wheels of the traveling carriage 520 are provided with encoders 523, and the rotation of the wheels, that is, the traveling of the traveling carriage 520 is measured. That is, the encoder 523 is a ladle position detection sensor that can detect the position of the processing ladle L1. In addition, the hot water receiving carriage 52 with an empty replacement function may include a ladle position detection sensor 59 (see FIG. 7) such as a photoelectric sensor described later. The hot water receiving carriage 52 with an empty replacement function includes a tilting device 526 for tilting the processing ladle L1 to replace the molten metal, and a tilting motor 527 for tilting the processing ladle L1 using the tilting device 526. The tilting device 526 and the processing ladle L1 are placed on the scissor lifter 524 on the traveling carriage 520 and moved up and down. Since the hot water receiving carriage 52 with an empty replacement function has a function of moving the processing ladle L1 up and down, the emptying from the processing ladle L1 to the pouring ladle L2 becomes easy. The hot water receiving carriage 52 with an air replacement function includes a load cell (first weigh scale) 525 that measures the weight of the molten metal received from the furnace F. Moreover, it has a non-contact thermometer (not shown) which measures the temperature of the molten metal received.

In the hot water receiving carriage 52 with the air exchange function, the cable reel 528 and the control panel 521 for receiving power from the outside are installed at a position away from the processing ladle L1, so that the molten metal is removed from the processing ladle L1. In case of leakage, these devices are not affected. Note that the control panel 521 may be installed not on the traveling carriage 520 but at a position along the rail R on which the traveling carriage 520 travels.

When the molten metal is put into the processing ladle L1 into which the alloy material has been charged and the alloy material and the molten metal react with each other, droplets of the molten metal are scattered or dust or gas is generated. Therefore, when the alloy material in the processing ladle L1 reacts with the molten metal, the processing ladle L1 is conveyed to the reaction position P3. A reaction chamber (not shown) is preferably provided at the reaction position P3. The reaction chamber surrounds the top of the treatment ladle L1 and discharges air through a duct. Therefore, it is possible to prevent molten liquid droplets from being scattered around and to discharge dust and dust.

As shown in FIG. 10, the molten metal transport unit 50 is different from the empty replacement position P4 of the processing ladle L1 for the sake of convenience. ), And a pouring ladle transport carriage 54 that transports the pouring ladle L2 to a transfer position P5 that transports the pouring ladle L2 to the pouring machine 72, and a pouring ladle transport carriage 54 run. Rail R. The pouring ladle transport carriage 54 includes a traveling carriage 540 that travels on a rail, a roller conveyor 544 that is installed on the traveling carriage 540 and moves in the horizontal direction of the pouring ladle L2, and a roller conveyor motor 546. The wheels of the traveling carriage 540 are provided with encoders 543, and the rotation of the wheels, that is, the traveling of the traveling carriage 540 is measured. That is, the encoder 543 is a ladle position detection sensor that can detect the position of the pouring ladle L2. In the pouring ladle transporting carriage 54, the cable reel 548 for receiving power from the outside and the control panel 541 are installed away from the pouring ladle L2, so that the molten metal is removed from the pouring ladle L2. In the event that leaks, these devices will not be affected. Note that the control panel 541 may be installed not on the traveling carriage 540 but at a position along the rail R on which the traveling carriage 540 travels. Moreover, between the transfer position P5 and the pouring machine 72, the pouring ladle conveyance mechanism 58 (refer FIG. 7) which conveys the pouring ladle L2 in the direction orthogonal to the running direction of the pouring ladle conveyance carriage 54. May be installed. The pouring ladle transport mechanism 58 may be a roller conveyor or the like. In addition, the capacity | capacitance of the process ladle L1 may be doubled to the capacity | capacitance of the pouring ladle L2, for example, and it may replace with one 2 pouring ladles L2.

You may have the empty inoculation apparatus 56 which adds an inoculum to the molten metal refilled from the process ladle L1 to the pouring ladle L2 near the empty position P4. The configuration of the air exchange inoculation device 56 is basically the same as that of the alloy material charging unit 60. By injecting the inoculum when the molten metal is emptied from the treatment ladle L1 to the pouring ladle L2, the inoculum can be uniformly introduced in a short time.

The molten metal conveyance unit 50 is configured to convey the treatment ladle L1 to the charging position P1, the hot water reception position P2, the reaction position P3, and the empty replacement position P4 as the ladle position of the treatment ladle L1, and the pouring ladle. There is a ladle position detection sensor 59 that detects that the pouring ladle L2 has been transported to the empty replacement position P4 and the transfer position P5 as the ladle position of the ladle L2. The ladle position detection sensor 59 may be a proximity switch or a laser sensor installed under the roller conveyor of the pouring ladle transport mechanism 58, for example, as shown in FIG. Alternatively, it may be the

encoder

523, 543 installed in the hot water receiving cart 52 with the air replacement function shown in FIG. 9 or the pouring ladle transport cart 54 shown in FIG. 10, or the hot water receiving cart 52 with the air replacement function. Alternatively, a photoelectric sensor installed in the pouring ladle transport carriage 54 may be used. In addition, it has a photoelectric sensor which confirms that the processing ladle L1 is mounted in the hot water receiving trolley 52 with an air exchange function, and that the pouring ladle L2 is mounted in the pouring ladle conveying cart 54. It is preferable.

As shown in FIG. 11, the pouring unit 70 includes a pouring machine 72 that pours the mold M from the pouring ladle L2. The pouring machine 72 is supported by the elevating mechanism 722 and the elevating mechanism 722 installed on the pouring machine carriage 720, which travels in parallel with the casting mold M being conveyed. The tilting mechanism 724 for tilting the pouring ladle L2 mounted thereon, the pouring machine rail Rp on which the pouring machine cart 720 travels, and the load cell for measuring the molten metal weight of the pouring ladle L2 (second weighing scale) 725. The elevating mechanism 722 is installed on a front / rear moving mechanism 728 that moves in a direction orthogonal to the direction in which the pouring machine cart 720 travels. Moreover, it has a non-contact thermometer (not shown) which measures the temperature of the molten metal to pour. The non-contact thermometer is preferably, for example, a fiber type so that the temperature measuring unit can be adjusted.

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

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

As shown in FIG. 12, the casting facility 1 includes a casting facility management computer 91 that manages the entire casting facility 1, and includes a control device in each unit. That is, the molding unit control device 11 is used for the molding unit 10, the mold transport unit 31 is used for the mold transport unit 30, the melt transport unit control device 51 is used for the melt transport unit 50, and the pouring unit control is used for the pouring unit 70. A device 71 is provided. Further, the alloy material charging unit 60 includes an alloy material charging unit controller 61. The TP collection unit 76 may include a TP collection unit controller. These control devices are installed in each unit, but the installation location is not limited. For example, the molten metal transport unit control device 51 may be configured by a control panel 521 of the hot water receiving carriage 52 with an empty replacement function and a control panel 541 of the pouring ladle transport truck 54. Moreover, the pouring unit control apparatus 71 may be installed on the pouring machine cart 720 as shown in FIG. 11, or may be installed at a position along the pouring machine rail Rp. Physically, the plurality of

control devices

11, 31, 51, 61, 71 may be in the same control device, or may be in the same computer as the casting facility management computer 91. The casting equipment management computer 91 may be any computer that can manage data, and its configuration is not particularly limited. Alternatively, the operations of the respective control devices and the casting facility management computer 91 may be performed by a computer at a location different from the casting facility 1 using cloud computing. Also in these cases, each unit is provided with each control device, and the casting equipment 1 is provided with the casting equipment management computer 91.

These

control devices

11, 31, 51, 61 and 71 include the device control PLC 102 shown in FIG. Alternatively, each of the control board 521 of the hot water receiving carriage 52 with an air replacement function and the control board 541 of the pouring ladle transport carriage 54 may include the device control PLC 102. Further, a device control PLC 102 may be installed in each device. Each

control device

11, 31, 51, 61, 71 is connected to the switching hub 110 and connected to the display screen 108 via the information storage PLC 104 and the computer 106. Alternatively, the casting equipment management computer 91 may function as the computer 106 having a program for converting into the screen display data shown in FIG. Then, the casting equipment management computer 91 may be connected to the display screen 108 that can be viewed from the place where the worker is normally working.

Next, the casting method and data management method in the casting facility 1 will be described with reference to FIGS. Based on the product plan, user input, etc., the molding plan data indicating a plan for molding the mold M by the molding unit 10, the mold M molded by the mold transport unit 30 is transported, and the mold M is processed such as drilling. Transportation plan data indicating a plan, molten metal transportation plan data indicating a molten metal transportation plan or replacement plan in the molten metal transportation unit 50, alloy material planning data indicating a plan of an alloy material and an inoculum to be charged in an alloy material charging unit 60, and In the pouring unit 70, pouring plan data indicating the pouring plan from the pouring ladle L2 to the mold M is input to the casting equipment management computer 91 or calculated by the casting equipment management computer 91. Note that the molding plan data, the conveyance plan data, the molten metal conveyance plan data, the alloy material plan data, and the pouring plan data may be combined as two or more and handled as a set of data. The molten metal transport plan data and the alloy material plan data are collectively referred to as molten metal plan data.

The molding plan data includes data such as model number, release agent application time, static pressure or squeeze pressure during molding, sand loading, mold height, mold thickness, compressibility, etc. The transfer plan data includes data such as gas drilling, gate shape and position, core set, intermittent mold transfer cycle time, and the like. The molten metal transfer plan data includes data such as a material number and a molten metal weight planned value. The alloy material plan data includes data such as the hopper number and the input weight from the hopper. The pouring plan data includes data such as pouring weight, cup position, pouring temperature, allowable fading time, and molten metal material corresponding to the mold.

The molding unit 10 molds the mold M based on the molding plan data. First, the property of the molding sand before molding is measured by the sand molding property measuring machine 12 before molding. The properties to be measured are compactability (CB), moisture, sand temperature, air permeability, mold strength (pressure resistance) and the like. The properties of the mold sand greatly affect the quality of the mold. The measured properties of the molding sand are stored in the molding unit controller 11 as molding history data.

Using the molding sand whose properties were measured, a mold (in this stage, an upper mold and a lower mold) is molded by the molding apparatus 14. A mold release agent is applied to a predetermined model, a predetermined amount of mold sand is placed, and the mold is pressed with a predetermined static pressure or squeeze pressure until a predetermined compression ratio is obtained, thereby forming a mold having a predetermined thickness and height. When the mold is formed, the molding unit control device 11 issues a mold serial number to the mold. When the mold serial number is issued, the molding plan data such as the measured properties of the mold sand is associated with the mold serial number. Further, molding history data such as sand input weight, compression rate, static pressure or squeeze pressure, squeeze time, pressurization speed, squeeze stroke, mold thickness, molding time, etc. is measured by the molding apparatus 14 and the mold serial number is obtained as molding history data. Associate with. The molding unit control device 11 transmits the mold serial number and the molding history data to the casting equipment management computer 91. The molding plan data and the molding history data are collectively called molding data. Further, the molding unit control device 11 transmits the mold serial number and the molding data associated with the mold serial number to the mold transport unit control device 31.

When the mold is formed by the molding apparatus 14, a mark for identifying the space is stamped by the stamping apparatus 16 on the inner surface of the space for manufacturing the casting in the mold. What is necessary is just to stamp on either an upper mold | type or a lower mold | type. In addition, when there are a plurality of spaces in one mold, that is, when a plurality of castings are manufactured with one mold, an identifiable mark is imprinted in each space. That is, an identifiable mark is attached to each obtained casting (product). When marking is performed by the marking device 16, the molding unit control device 11 issues an individual identification serial number corresponding to each marking. Moreover, the molding unit control apparatus 11 associates the issued individual identification serial number with the mold serial number. When the marking device 16 is installed in the mold transport unit 30, the individual identification serial number is issued by the mold transport unit control device 31, and is associated with the mold serial number by the mold transport unit control device 31.

The mold transport unit 30 transports the mold M based on the mold transport plan data, makes the mold M ready for pouring, cools the poured mold, that is, the molten metal, and separates the casting from the sand. . In the mold transport unit 30, the mold is intermittently sent by the pusher 38 frame by frame. The traverser T also transfers the molds one by one to the adjacent mold row. Also, a hole is made in the mold by the gas drilling device 40, the upper mold and the lower mold are reversed by the upper and lower mold reversing machine 41, the mold space is directed upward, and the sand on the upper surface of the upper mold is removed by the sand cutter 42. Remove the gate and open the gate to the upper mold with the gate cutter 43. Further, the mold is placed on the surface plate carriage by the surface plate carriage set device 44, the core is set on the upper mold and the lower mold by the core setter 45, the upper mold is reversed by the upper mold re-reversing machine 46, and the mold is aligned. The mold transfer device 47 combines the upper mold and the lower mold to form one mold M. History data in these processes, for example, gas drilling information, gate opening information, core information, and the like are collected as molding data (mold history data) and associated with mold serial numbers. As described above, the mold transport unit 30 collects the molding data while transporting the mold. When a defect occurs in these processes, the mold conveyance unit control device 31 associates the defect information with the mold serial number of the mold M. In the case of a frameless mold, some or all of the above-described gas drilling information, gate opening information, core information, etc. are obtained by the molding unit 10 and associated with the mold serial number by the molding unit controller 11. May be.

As shown in FIG. 13, every time the mold transport unit control device 31 transports the mold, the mold position detection sensor 39 detects the transport of the mold and shifts the mold serial number. A mold serial number “n” is issued to the mold molded by the molding apparatus 14. When the mold transport unit 30 detects that the mold has been transported for one frame, the mold serial number “n” is shifted to the next position. The mold serial numbers are assigned to all the stop positions in the intermittent conveyance of the mold, and by shifting all the mold serial numbers, the mold positions and the mold serial numbers correspond correctly.

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

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

The processing ladle L1 charged with the alloy material is transported to the hot water receiving position P2 by the hot water receiving carriage 52 with an air replacement function of the molten metal transport unit 50. The treatment ladle L1 receives molten metal from the furnace F. When the molten metal is received, the weight of the molten metal received by the load cell 525 as the first weighing scale, and the temperature measured by the non-contact thermometer are measured. The molten metal transport unit control device 51 associates the measured weight, temperature, tapping furnace number, charge number, material number, time of receiving hot water, etc. with the ladle serial number of the processing ladle L1 as molten state data. Furthermore, the data regarding the property of the molten metal melted in the furnace F may be received, and the data may be included in the molten state data. Note that the molten metal melted in the furnace, the molten metal received in the treatment ladle, and the molten metal reacted with the alloy material are simply referred to as “molten metal” in this specification.

The treatment ladle L1 that has received the hot water is transported to the reaction position P3 by the hot water receiving carriage 52 with an empty replacement function. When the reaction between the molten metal and the alloy material is intense, the alloy material charging unit 60 puts the alloy material into the processing ladle L1, and then covers the alloy material with a cover agent such as steel scrap, so that the molten metal contacts the alloy material. suppress. Therefore, immediately after receiving the hot water in the treatment ladle L1, no severe reaction occurs, and during that time, the treatment ladle L1 can be moved to the reaction position P3. When the alloy material contains a spheroidizing element such as Mg, severe bubbling occurs when the reaction starts. Therefore, the measurement value in the load cell 525 varies greatly. Therefore, the time when the measurement value at the load cell 525 greatly fluctuates and then becomes smaller than the predetermined value can be recognized as fading start. The molten metal transport unit control device 51 may associate a fading start time or a fading elapsed time that is an elapsed time from the fading start time as a molten metal state data with a ladle serial number. The fading start time or elapsed time associated with the ladle sequence number is transmitted to the pouring unit control device 71. Thus, in the molten metal conveyance unit control apparatus 71, molten metal state data is collected and conveyed to the ladle serial number while conveying the treatment ladle L1 and the pouring ladle L2.

When the reaction between the molten metal and the alloy material is completed, the treatment ladle L1 is conveyed to the empty replacement position P4 by the hot water receiving carriage 52 with an empty replacement function. In the empty replacement position P4, an empty pouring ladle L2 is transported by the pouring ladle transport carriage 54 and is on standby. Therefore, the molten metal is replaced from the treatment ladle L1 to the pouring ladle L2. Here, in the hot water receiving trolley 52 with the air replacement function, the processing ladle L1 is set to a desired height by the scissor lifter 524, and the processing ladle L1 is tilted and replaced, so that it can be replaced safely and efficiently. In addition, during conveyance of the processing ladle 1, the processing ladle 1 is lowered | hung and it moves to the position near the center of the traveling cart 520, and the influence by the shaking of the traveling cart 520 can be made small.

When the replacement is completed, the ladle sequence number associated with the processing ladle L1 is associated with the pouring ladle L2. Thereafter, the hot water receiving carriage 52 with the air replacement function conveys the processing ladle L1 to the charging position P1, and is repeated from the charging of the alloy material. Note that two pouring ladles L2 and a pouring machine 72 may be provided, and the molten metal may be replaced from one processing ladle L1 to two pouring ladles L2. When it takes time to pour, the efficiency of the casting facility 1 can be improved by pouring from the pouring ladle L2 to the mold M using a plurality of pouring machines 72. When one processing ladle L1 is replaced with two pouring ladles L2, the second pouring ladle L2 has a ladle serial number for the processing ladle L1 and the second ladle. Data indicating that the hot water ladle has been replaced is associated as a ladle serial number. In addition, you may add an inoculum from the empty exchange inoculation apparatus 56 to the molten metal refilled from the process ladle L1 to the pouring ladle L2. The molten metal transport unit control device 51 associates the type, weight and addition time of the added inoculum with the ladle sequence number as molten metal state data.

When the molten metal is replaced in the pouring ladle L2, the pouring ladle conveying cart 54 conveys the pouring ladle L2 to the transfer position P5. The pouring ladle L <b> 2 is transferred from the transfer position P <b> 5 to the pouring position P <b> 6 by the pouring ladle transport mechanism 58 and is held by the pouring machine 72. The molten metal transport unit control device 51 transmits the ladle sequence number and the molten metal state data associated with the ladle sequence number to the casting equipment management computer 91. In addition, when a malfunction occurs in the molten metal conveyance in the pouring conveyance unit 50, information on the malfunction is transmitted to the casting equipment management computer 91 in association with the pan sequence number.

As shown in FIG. 14, the molten metal transport unit 50 has a ladle position at the pouring position P1, the hot water receiving position P2, the reaction position P3, the empty replacement position P4, and the pouring ladle L2 at the transfer position P5. It is detected by the detection sensor 59 (or encoder 523, 543), and the ladle serial number is shifted. Then, the molten metal state data is associated with the ladle serial number. Therefore, the position of the processing ladle L1 or the pouring ladle L2 and the ladle serial number correspond correctly, and the molten metal state data from different apparatuses are correctly associated with the ladle serial number.

When the mold M is transported before the pouring machine 72, the mold transport unit controller 31 transmits the mold serial number of the mold M to the pouring unit controller 71. Then, the pouring unit control device 71 receives the pouring plan data from the casting equipment management computer 91, and further, the ladle sequence number of the pouring ladle L2, the received hot water weight, the allowable amount from the molten metal transport unit control device 51. Receives fading time, fading start time, fading elapsed time, etc. Note that the pouring unit control device 71 may measure the fading elapsed time by receiving the fading start time without receiving the fading elapsed time.

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

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

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

The pouring unit control device 71 stores a pouring pattern and performs pouring with a pouring pattern applied to the mold associated with the mold serial number. During pouring, image data of the pouring gate is acquired by the pouring surface detection camera 726. The pouring unit control device 71 calculates the hot water level based on the image data, and controls the tilting of the pouring ladle L2 in the tilting mechanism 724. During the pouring, the weight of the molten metal in the pouring ladle L2 is measured by the load cell 725, and the pouring unit controller 71 calculates the amount of the molten metal poured into the mold M. When the weight of the poured molten metal approaches the target value, drain the hot water. In addition, the casting_mold | template M is intermittently conveyed also in front of the pouring machine 72 like other places. Therefore, when the pouring to the mold M is not completed within the time when it is stopped, the pouring machine cart 720 travels at the same speed as the mold M being conveyed, and the pouring to the mold M is continued. be able to. In addition, when the time for pouring from the pouring machine 72 is longer than the interval at which the mold is intermittently conveyed, two pouring machines 72 are used. That is, two pouring ladles L2 are used.

The pouring unit control device 71 compares the fading elapsed time and the allowable fading time as appropriate. When the elapsed fading time exceeds the allowable fading time, an error signal is generated and pouring from the pouring ladle L2 is stopped even if the molten metal remains in the pouring ladle L2. Therefore, spheroidization failure due to fading can be prevented. The molten metal remaining in the pouring ladle L2 is returned to the melting furnace F and reused by using a conveying device that returns the molten metal to the melting furnace F.

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

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

In the mold conveyance unit 30, the poured mold M is conveyed in the cooling zone 34. In the cooling zone 34, the rail Rf is long, and it takes time to be transported. During that time, the molten metal in the mold M is cooled and solidified. When the mold M is conveyed to the mold separating device 48 downstream of the cooling zone 34, the mold M is disassembled and the casting and the sand are separated. The casting is sent to a subsequent process to make a product. The sand is sent to the molding unit 10 through a sand collecting device (not shown). When the error signal and the TP inspection result associated with the mold serial number of the mold M conveyed to the mold separating apparatus 48 are defective, the mold conveyance unit control device 31 does not send the separated casting to the subsequent process. Distinguish as follows. Therefore, it is possible to prevent defective products from being shipped as products. The mold conveyance unit control device 31 associates the mold serial number with the casting sent to the subsequent process. Further, the mold serial number and the molding history data are transmitted to the casting equipment management computer 91.

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

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

Here, with reference to FIG. 15 as well, an operation for performing data processing in units of molds and an operation for performing data processing in units of ladles will be described together. Molding is performed by the molding apparatus 14 using the sand sand that has been subjected to sand treatment and whose properties have been measured by the pre-molding sand characteristics. A mold serial number is issued to the molded mold here, and data processing for each mold unit is performed using the mold serial number. Note that the exchange of the shape of the mold and the like is performed by exchanging a casting frame, a model, and the like used in the molding apparatus 14. Gas drilling, raising frame reversal, sand cut, gate cut, surface plate carriage set, core set, upper mold re-reversal, mold alignment, etc., as the process to process the molded mold, use mold unit data, history Is recorded in the mold unit.

When the alloy material is put into the processing ladle L1 placed on the hot water receiving carriage 52 with an air exchange function, a ladle serial number is issued to the processing ladle L1. Thereafter, data processing for each ladle is performed using the ladle serial number. The movement of the treatment ladle L1 to the hot water receiving position P2, the reaction position P3, and the empty replacement position P4, the hot water receiving from the melting furnace F, the pouring ladle L2 placed on the pouring ladle transport carriage 54 Emptying, moving the pouring ladle L2 to the transfer position P5, transporting the pouring ladle L2 to the pouring machine 72, pouring the mold in the pouring machine 72, TP in the TP sampling unit 76 For collection, etc., data for each ladle is used, and history (status data) is also recorded for each ladle.

When pouring into the mold by the pouring machine 72, the ladle sequence number is associated with the mold sequence number, and the data associated with the ladle sequence number can be extracted from the mold sequence number. That is, the mold cooling time in the cooling zone can vary depending on, for example, the molten metal pouring weight, so that the length of the molten metal drawn from the mold serial number may be changed for each mold and conveyed in the cooling zone. Specifically, what traverser T is used to move the mold to the adjacent mold rail Rf or which mold rail Rf is moved by the traverser T may be changed. Further, when the mold disassembly device 48 disassembles the mold, if the molten state data drawn from the mold serial number includes a defect, the disintegrated casting is distinguished from the casting as a product, for example, disposal. You can also

Next, a casting facility 2 different from the casting facility 1 in FIG. 6 will be described with reference to FIGS. 16 and 17. In the casting facility 2, the molten metal is received from the furnace F into the pouring ladle L <b> 2 and transferred to the pouring machine 72 without being replaced. Since the other points are the same as those of the casting equipment 1, overlapping description is omitted and only different points will be described. When the reaction between the molten metal and the alloy material is not so violent, it is not necessary to cause the reaction in the treatment ladle L1, and the reaction can be performed by receiving the hot water in the pouring ladle L2.

The molten metal transfer unit 50 includes an alloy material charging unit 60, a molten metal ladle transporting carriage 84 that conveys the molten metal ladle L2 to the charging position P1, the hot water receiving position P2, the reaction position P3, and the transfer position P5, A rail R on which the pan transport carriage 84 travels and a pouring ladle transport mechanism 58 that transports the pouring ladle L2 from the transfer position P5 to the pouring machine 72 are provided. When the reaction is gentle, the reaction position P3 is not particularly defined, and the molten metal and the reaction alloy material may be reacted during conveyance.

As shown in FIG. 18, the pouring ladle transport carriage 84 includes a traveling carriage 840 that travels on the rail R, a guide pillar 842 that is installed on the traveling carriage 840, and extends horizontally from the guide pillar 842. There is a lifting frame 844 that can be moved up and down, a ladle moving mechanism 846 that is installed on the lifting frame 844 and moves the pouring ladle L2 in the horizontal direction, and a lifting frame lifting device 848 that lifts and lowers the lifting frame 844. The elevating frame elevating device 848 elevates the elevating frame 844 by winding up the chain 848C by the rotation of the motor 848M. For example, even if the construction time of the melting furnace F and the pouring unit 70 is different and there is a difference in the installation height, the pouring ladle transport carriage 84 has a function of moving the pouring ladle L2 up and down. The difference in height can be absorbed. The pouring ladle transport carriage 84 has a load cell (first weighing scale) 845 for measuring the weight of the molten metal received from the furnace F. Moreover, it has a non-contact thermometer (not shown) which measures the temperature of the molten metal received.

The pouring ladle transport truck 84 is provided with a power receiving device 849 and a motor 848M for receiving power from the outside at a high position and a position away from the pouring ladle L2. When the molten metal leaks from L2, these devices are not affected. The high position is a position higher than the bottom of the pouring ladle L2 when the pouring ladle transport carriage 84 travels, that is, when the lifting frame is lowered. The position away from the pouring ladle L2 is the position on the opposite side across the guide column 842.

Also in the casting facility 2, when an alloy material is introduced into the pouring ladle L2 from the alloy material feeding unit 60, a ladle serial number is issued to the pouring ladle L2. When the molten metal state data is associated with the ladle sequence number and poured into the mold M from the pouring machine 72, the ladle sequence number is associated with the mold sequence number. Therefore, the same effect as the casting equipment 1 can be obtained.

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

The data transfer between the

unit control devices

11, 31, 51, 61, 71 and the casting equipment management computer 91 described in this specification is not limited to the above, and may be changed as appropriate. The data shown as each plan data, mold history data, and molten state data is an example, and other data may be used.

The main symbols used in the present specification and drawings are summarized below.
DESCRIPTION OF SYMBOLS 1, 2 Casting equipment 10 Molding unit 11 Molding unit control apparatus 12 Pre-molding sand characteristic measuring machine 14 Molding apparatus 16 Stamping measure 30 Mold conveyance unit 31 Mold conveyance unit control apparatus 32 Molding line 33 Mold conveyance unit pouring zone 34 Mold conveyance unit Cooling zone 36 Mold transfer lane 37 Mold position detection encoder 38 Mold feed pusher (transport mechanism)
39 Mold position detection sensor 40 Gas drilling device 41 Upper and lower mold reversing machine 42 Sand cutter 43 Spout cutter 44 Surface plate carriage set device 45 Core setter 46 Upper mold reversing device 47 Mold alignment / mold transfer device 48 Mold spreading device 50 Molten metal transport Unit 51 Molten metal transfer unit control device 52 Hot

water receiving carts

54 and 84 with an empty exchange function Pouring ladle conveying cart 56 Empty inoculation device 58 Pouring ladle conveying mechanism 59 Ladle position detection sensor 60 Alloy material input unit 61 Alloy material Input unit control device (alloy material input control device)
62 Alloy material hopper 70 Pouring unit (molten transfer unit)
71 Pouring unit control device 72 Pouring machine 76 Test piece (TP) sampling unit 91 Casting equipment management computer 100 Information display system 102 Device control PLC
104 PLC for information storage
106 Computer 108 having program for converting to screen display data Display screen 110 Switching hub 112 Wireless communication device 520 Traveling carriage 521 Control panel 522 Traveling motor 523 Encoder (position detection sensor)
524 Scissor lifter (lifting function)
525 Load cell (first weighing scale)
526 Tilt device 527 Tilt motor 528 Cable reel 540 Traveling carriage 541 Control panel 542 Traveling motor 543 Encoder (Ladle position detection sensor)
544 Roller conveyor 546 Roller conveyor motor 548 Cable reel 720 Pouring machine cart 722 Lifting mechanism 724 Tilt mechanism 725 Load cell (second weighing scale)
726 Molten surface detection camera 728 Back and forth movement mechanism 840 Traveling carriage 842 Guide column 843 Encoder 844 Lifting frame 845 Load cell (first weighing scale)
846 Ladle moving mechanism 848 Elevating frame elevating device 849 Power receiving device F Melting furnace L1 Treatment ladle L2 Pouring ladle M Mold P1 Loading position P2 Hot water receiving position P3 Reaction position P4 Empty position P5 Transfer position P6 Pouring position R Rail Rf Mold rail Rp Pouring machine rail T Traverser

Claims

An information display system for displaying information on a plurality of devices constituting the casting equipment in a casting equipment for forming a mold and transporting the mold to a pouring position and obtaining a casting by pouring the mold. ,
A device control PLC that controls at least one device of the casting facility and stores information related to the device;
A computer having a program for converting information stored in the plurality of device control PLCs into screen display data for displaying on the screen, the information relating to the plurality of devices;
A display screen for displaying information stored in the device control PLC based on screen display data obtained by the computer program;
Displaying information on the plurality of devices on a single screen so that an operator can grasp information on the entire casting facility,
Information display system.
The device control PLC stores information measured by a sensor installed in the device.
The information display system according to claim 1.
An information storage PLC that converts information stored in the device control PLC into information to be displayed on the screen;
The computer uses the information stored in the information storage PLC to convert to the screen display data.
The information display system according to claim 2.
The device control PLC and the information storage PLC are connected by a LAN via a switching hub.
The information display system according to claim 3.
The information displayed on the screen includes one or more information among production information of the casting, operation information of the apparatus, molding sand information, and inspection standard information.
The information display system according to claim 4.
The production information of the casting includes one or more pieces of information among a planned production number, a current production number, an achievement rate, a defect rate, a model number, and a product number.
The information display system according to claim 5.
The operation information of the apparatus includes one or more information among the operation status of the casting equipment, a cycle time for molding the mold, and a cycle time for pouring the mold.
The information display system according to claim 6.
The molding sand information includes one or more information of molding sand temperature, CB value, moisture, air permeability and compressive strength, and atmospheric temperature.
The information display system according to claim 7.
The inspection standard information includes a product number, a model number, a lot number, and one or more pieces of information among appearance inspection standards corresponding to the model number and the lot number.
The information display system according to claim 8.
A second computer different from the computer is connected to the display screen via a LAN, and information stored in the second computer is displayed on the display screen.
The information display system according to claim 9.
The casting equipment is
A molding unit for molding a mold from mold sand;
A mold transport unit for transporting the molded mold;
A pouring unit for pouring the mold carried by the mold carrying unit;
A casting equipment management computer for controlling the casting equipment,
The molding unit has a molding device that molds the mold, and a molding unit control device that controls the operation of the molding device,
The molding unit control device receives molding plan data from the casting equipment management computer, controls the molding unit to mold a mold with a molding plan corresponding to the molding plan data, and for a mold that has been molded The mold serial number is issued, and the mold serial number is associated with molding data relating to the mold,
The mold transport unit includes a transport mechanism that transports the mold one mold at a time, a mold position detection sensor that detects that the mold has been transported, and a mold transport unit controller that controls the operation of the mold transport unit. Have
The mold transport unit control device controls the transport mechanism to intermittently transport the mold, receives the mold serial number of the mold that is molded by the molding apparatus and is transportable by the transport mechanism, By shifting the mold serial number assigned to the mold position where the mold stops in accordance with the movement of the mold detected by the mold position detection sensor, the mold position and the mold serial number of the mold at the mold position are associated with each other. Let
The pouring unit has a pouring machine for pouring molten metal from a pouring ladle into a mold, and a pouring unit control device for controlling the operation of the pouring machine,
The pouring unit control device receives a ladle serial number associated with the molten state data of the molten metal in the pouring ladle, and receives a mold serial number of the mold at the pouring position from the mold transport unit control device. The pouring machine is controlled to perform pouring according to the pouring plan corresponding to the pouring plan data corresponding to the mold serial number received, and the ladle serial number of the poured ladle is poured into the mold. Send to the casting equipment management computer in association with the serial number,
The mold serial number and the molding data associated with the mold serial number, and the ladle serial number and the molten state data associated with the molten state data are displayed on the display screen.
The information display system according to claim 1.
The casting equipment is
A molding unit for molding a mold from mold sand;
A mold transport unit for transporting the molded mold;
A pouring unit for pouring the mold carried by the mold carrying unit;
A casting equipment management computer for controlling the casting equipment,
The molding unit has a molding device that molds the mold, and a molding unit control device that controls the operation of the molding device,
The molding unit control device receives molding plan data from the casting equipment management computer, controls the molding unit to mold a mold with a molding plan corresponding to the molding plan data, and for a mold that has been molded The mold serial number is issued, and the mold serial number is associated with molding data relating to the mold,
The mold transport unit includes a transport mechanism that transports the mold one mold at a time, a mold position detection sensor that detects that the mold has been transported, and a mold transport unit controller that controls the operation of the mold transport unit. Have
The mold transport unit control device controls the transport mechanism to intermittently transport the mold, receives the mold serial number of the mold that is molded by the molding apparatus and is transportable by the transport mechanism, By shifting the mold serial number assigned to the mold position where the mold stops in accordance with the movement of the mold detected by the mold position detection sensor, the mold position and the mold serial number of the mold at the mold position are associated with each other. Let
The pouring unit has a pouring machine for pouring molten metal from a pouring ladle into a mold, and a pouring unit control device for controlling the operation of the pouring machine,
The pouring unit control device receives a ladle serial number associated with the molten state data of the molten metal in the pouring ladle, and receives a mold serial number of the mold at the pouring position from the mold transport unit control device. The pouring machine is controlled to perform pouring according to the pouring plan corresponding to the pouring plan data corresponding to the mold serial number received, and the ladle serial number of the poured ladle is poured into the mold. Send to the casting equipment management computer in association with the serial number,
The mold serial number and the molding data associated with the mold serial number, and the ladle serial number and the molten state data associated with the molten state data are displayed on the display screen.
The information display system according to claim 10.
The molding unit controller serves as the device control PLC of the molding apparatus for molding the mold.
The mold transport unit controller also serves as the device control PLC of the mold transport device that transports the mold to the pouring position.
The pouring unit controller also serves as the device control PLC of the pouring device for pouring the mold.
The information display system according to claim 11.
The molding unit controller serves as the device control PLC of the molding apparatus for molding the mold.
The mold transport unit controller also serves as the device control PLC of the mold transport device that transports the mold to the pouring position.
The pouring unit controller also serves as the device control PLC of the pouring device for pouring the mold.
The information display system according to claim 12.