WO2018142977A1 - System for detecting causes of abnormalities in plurality of devices constituting casting equipment - Google Patents

Abstract

Provided is a system that intensively monitors the operating data of a plurality of devices constituting casting equipment, and identifies the true causes of abnormalities in order to detect the causes of abnormalities that occur in the devices. The system (100) is provided with: sampling PLCs (102) that monitor and store information pertaining to the operation of at least one device among a plurality of devices; and an abnormality-determining computer (108) that receives, from a plurality of sampling PLCs, information pertaining to the operation of a plurality of devices, determines an abnormality in a device on the basis of information pertaining to the operation of the device, and stores the operating states of a plurality of devices causing the abnormality in the device. When determining the abnormality in at least one device among the plurality of devices from information pertaining to the operation of the device, on the basis of the stored operating states of the plurality of devices, the operating state causing the abnormality is identified from the received information pertaining to the operation of the plurality of devices. [Selected drawing] FIG. 1

Description

A system for detecting the cause of abnormality in a plurality of devices constituting a casting facility

The present invention relates to a system that detects the cause of abnormality of a plurality of devices that constitute a casting facility, and relates to a system that can identify the cause even when an abnormality of a certain device is caused by another device.

The casting is obtained by forming a mold, transporting the mold to a pouring position, and pouring the mold. For this purpose, the foundry has facilities for adjusting the molding sand (sand treatment), molding the mold, molding and setting the core as necessary, and feeding the mold. There is also a facility 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 equipment (post-treatment) for cooling the molten metal in the mold and separating the cast product and the mold sand. In this way, the casting equipment is a combination of a large number of devices, and these devices are operating in a related manner.

Casting equipment is equipped with a dedicated control device for each equipment. For example, Patent Document 1 collects operation data from a motor such as a load current value and a rotation speed during operation and monitors an operation state so that efficient maintenance can be performed.

However, in a casting facility apparatus in which a plurality of apparatuses are operating in association with each other, there is a case where the true failure cause of the failed apparatus is not in the apparatus itself but in another apparatus. Therefore, even if only the data of the device is monitored, there are cases where extra maintenance work and useless inspection work occur.

Therefore, the present invention provides a system for centrally monitoring operation data of a plurality of apparatuses and identifying the true cause of the abnormality in order to detect the cause of the abnormality occurring in the plurality of apparatuses constituting the casting equipment. For the purpose.

JP 2002-95219 A

In order to solve the above problems, a system according to a first aspect of the present invention, as shown in FIG. 1, for example, molds a mold, transports the mold to a pouring position, and pours the mold into the mold. A system 100 for detecting the cause of an abnormality of a plurality of apparatuses constituting a casting facility for obtaining a casting, and monitoring and storing information relating to the operation of at least one of the plurality of apparatuses; An abnormality determination computer that receives information related to operation of the plurality of devices from a plurality of sampling PLCs 102, and determines a failure of the device from information related to operation of the device, and causes a plurality of causes of the abnormality of the device And an abnormality determination computer 108 that stores the operation status of the apparatus, and information regarding the operation of at least one of the plurality of apparatuses When determining the abnormality of Luo said device, based on the operation status of plural device storing, identifies the operating state that causes the abnormality from information about the operation of a plurality of devices received. When configured in this way, for an anomaly that occurred in one of the multiple devices that make up the casting facility, the operating status of the multiple devices was examined based on the operating status that caused the stored anomaly, and occurred in a certain device It becomes a system to identify the true cause of the abnormalities.

Further, in the system according to the second aspect of the present invention, for example, as shown in FIG. 1, in the system 100 according to the first aspect, the plurality of devices measure a current value for operating the device. The sampling PLC 102 has an ammeter or a voltmeter that measures a voltage value, and monitors the current value or the voltage value as information related to operation. If comprised in this way, the load concerning an apparatus can be measured as an electric current value or a voltage value, and operation | movement of an apparatus can be monitored.

Further, as shown in FIG. 1, for example, in the system 100 according to the third aspect of the present invention, in the system 100 according to the first or second aspect, the plurality of devices are sound level meters that measure noise of the device. Or it has a vibrometer which measures vibration, and PLC102 for sampling monitors noise or vibration as information about operation. If comprised in this way, the noise or vibration which generate | occur | produces in an apparatus can be measured, and the abnormality which generate | occur | produced in the apparatus can be detected.

Further, the system according to the fourth aspect of the present invention is a system 100 according to any one of the first to third aspects, for example, as shown in FIG. 1, in which the sampling PLC 102 and the abnormality determination computer 108 are switched. They are connected by a LAN via the hub 104. If comprised in this way, the information of PLC for sampling of a some apparatus will be appropriately transmitted to the abnormality determination computer.

Further, the system according to the fifth aspect of the present invention is a system 100 according to any one of the first to fourth aspects as shown in FIGS. 1, 2, 3, 4, and 8, for example. A mold transport unit 30 for transporting the molded mold M, a pouring unit 70 for pouring the mold M transported by the mold transport unit 30, and a casting facility management computer 91 for controlling the casting facility 1 are provided. 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. The data is transmitted to the casting equipment management computer 91 in association with the serial number.

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. From the cause of the abnormality determined by the abnormality determination computer, the operator can identify a product that may have a problem based on the information managed in this way.

Further, the system according to the sixth aspect of the present invention is the same as the system 100 according to the fifth aspect in that the molding unit control device 11 is an abnormality determination computer as shown in FIGS. 1, 2, 3 and 8, for example. Also serves as 108. If comprised in this way, the cause of abnormality of the apparatus of a molding unit can be judged with a molding unit control apparatus.

In addition, the system according to the seventh aspect of the present invention is the same as the system 100 according to the fifth or sixth aspect, as shown in FIG. 1, FIG. 2, FIG. 3, and FIG. It also serves as the abnormality determination computer 108. If comprised in this way, the cause of abnormality of the apparatus of a mold conveyance unit can be judged with a mold conveyance unit control apparatus.

Further, the system according to the eighth aspect of the present invention includes a pouring unit in the system 100 according to any one of the fifth to seventh aspects as shown in FIGS. 1, 2, 3, and 8, for example. The control device 71 also serves as the abnormality determination computer 108. If comprised in this way, the cause of abnormality of the apparatus of a pouring unit can be judged with the pouring unit control apparatus.

Further, the system according to the ninth aspect of the present invention is the same as the system 100 according to the fifth aspect in that the casting equipment management computer 91 is an abnormality determination computer as shown in FIGS. Also serves as 108. If comprised in this way, the cause of abnormality of the apparatus of the whole casting installation can be judged with a casting installation management computer.

Further, the system according to the tenth aspect of the present invention is the same as the system 100 according to the fifth to ninth aspects, as shown in FIGS. 1, 2, 3 and 15, for example. The abnormality determination computer 108 further includes a sand processing unit 80 that adjusts the molding sand supplied to the unit 10 to a property suitable for molding, and a core molding unit 82 that molds the core disposed in the mold M. The defect state of the casting cast in the casting facility 1 and the cause of the defect in the unit are stored in the matrix database, and the malfunction of the apparatus is determined using the data of the matrix database from the information on the operation of at least one apparatus. judge. If comprised in this way, the malfunction of the apparatus which causes the defect of a casting can be determined quickly and reliably from a matrix database.

Further, the system according to the eleventh aspect of the present invention is the system 100 according to the tenth aspect, for example, as shown in FIG. 15, in which the matrix database includes the state of casting failure, sand treatment, molding, core , The processing points divided into six processing points of pouring, cooling, and post-processing. If comprised in this way, the malfunction in six process points can be determined quickly and reliably from the state of the defect of a casting.

The system according to the twelfth aspect of the present invention is the system 100 according to the tenth or eleventh aspect, in which the casting equipment 1 causes a problem in order to eliminate the problem based on the determined problem. Adjustment means for adjusting the apparatus is further provided. If comprised in this way, after determining quickly and reliably the apparatus which causes the casting defect using the matrix database, the apparatus causing the defect can be adjusted by the adjusting means, and the defect can be solved. .

In addition, the system according to the thirteenth aspect of the present invention is the system 100 according to the twelfth aspect, for example, as shown in FIGS. Either the device 31 or the pouring unit control device 51. With this configuration, the molding unit control device, the mold transport unit control device, and the pouring unit control device that control the operations of the molding unit, the mold transport unit, and the pouring unit adjust the devices that cause problems. , It is possible to efficiently adjust the defect.

According to the system for forming a mold of the present invention, transporting the mold to a pouring position, and detecting a cause of abnormality of a plurality of apparatuses constituting a casting facility for pouring the mold to obtain a casting, It is possible to centrally monitor the operation data of the device and identify the true cause of the abnormality.

This application is based on Japanese Patent Application No. 2017-018486 filed on February 3, 2017 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 of a system example for detecting a cause of abnormality of a plurality of apparatuses constituting a casting facility. FIG. 2 is a plan view showing the configuration of the casting equipment, showing 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. 3 is an enlarged view of a portion A in FIG. FIG. 4 is a diagram showing a mold feed pusher for conveying a mold and a sensor for detecting the operation thereof. FIG. 5 is a side view of a hot water receiving cart with an air replacement function. FIG. 6 is a side view of the pouring ladle transport cart. FIG. 7 is a side view of the pouring machine. FIG. 8 is a block diagram showing data acquired in each unit of the casting facility and data communication between the units. FIG. 9 is a schematic diagram for explaining how the mold serial numbers are shifted. Drawing 10 is a mimetic diagram explaining the position of a ladle, a ladle serial number, and molten metal state data related with a ladle serial number. FIG. 11 is a flowchart showing the flow of data in the casting facility. FIG. 12 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. 13 is an enlarged view of a portion B in FIG. FIG. 14: is a side view of the pouring ladle conveyance trolley with a raising / lowering function. FIG. 15 schematically shows an example of a matrix database representing the relationship between the state of a casting defect and the cause or defect.

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, referring to FIG. 1, a system 100 for detecting the cause of an abnormality in a plurality of apparatuses constituting a casting facility as an embodiment of the present invention will be described. In the figure, a plurality of devices constituting the casting facility are omitted, but reference numeral 102 denotes a sampling PLC installed in each device. The sampling PLC 102 monitors and stores information related to the operation of each apparatus. The information related to the operation of each device includes information measured by a sensor installed in each device. Note that the sampling PLC 102 may control the operation of the apparatus. Here, although each apparatus is apparatuses, such as a molding apparatus, a kneading machine, a pouring machine, a surface treatment apparatus, a dust collector, a melting furnace, for example, it is not limited to these. 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. A sensor (measuring instrument) for measuring the molding history data, an ammeter for measuring current for operation, a voltmeter for measuring voltage, a vibration meter, a sound level meter, and the like are not limited thereto.

The plurality of sampling PLCs 102 are connected to the abnormality determination computer 108 via the switching hub 104 via a LAN. When the sampling PLC 102 and the switching hub 104 of a certain apparatus are in a position where visibility is good, they may be connected via a wireless communication device 106 via a wireless LAN. However, a wired LAN connection is preferable because of high communication reliability. Note that the sampling PLC 102 and the abnormality determination computer 108 may be LAN-connected via a simple hub instead of the switching hub 104.

The abnormality determination computer 108 receives information related to the operation of each device from a plurality of sampling PLCs 102 including information measured by sensors installed in each device, and determines an abnormality of the device from the information. That is, when a certain value is out of a predetermined range or greatly changes from the previous value, it is determined that the device is abnormal. The predetermined range may be set so as to be changed, for example, by a change in the operation mode.

If it is determined that a certain device is abnormal, the abnormality determination computer 108 detects the cause. The abnormality determination computer 108 stores operating states of a plurality of apparatuses that cause an abnormality of a certain apparatus. Therefore, when an abnormality occurs in a certain device, the operating status of not only that device but also other devices is examined. The operating status to be checked is an operating status including a history.

Suppose, for example, that the squeeze pressure is high in the molding machine and it is determined that the molding machine is abnormal. The cause may be a failure of the molding machine valve, electrical system or other components, but there is an abnormality in the kneading machine, CB (contactability) controller, aerator, etc. in the previous process of the molding machine. There is also. The kneading machine is not operating normally, the properties of the mold sand sent to the molding machine may be poor, and the squeeze pressure of the molding machine may increase. The cause of this is to compare the data with the sand temperature in the kneader, the moisture value of the sand, the current value of the kneader, etc., that is, the sand temperature that increases the squeeze pressure of the molding machine. Can be specified. Similarly, it is possible to determine the cause by examining whether the operating status of the CB (contactability) controller and aerator is an operating status that increases the squeeze pressure of the molding machine.

Suppose also that the belt conveyor stopped abnormally due to overload. The cause may be a malfunction of the motor system of the belt conveyor, or an abnormality of the belt conveyor itself, such as biting of the conveyor belt or belt drive, but it is caused by an abnormality of the kneading machine in the previous process of the belt conveyor. In some cases. For example, it is conceivable that water is poured excessively into the mold sand with a kneader and the specific gravity of the sand becomes too large, and the belt conveyor stops due to overload. The cause of this is to examine the data storing the sand temperature, sand moisture value, kneader current value, etc. in the kneader, that is, data that increases the amount of water injected into the mold sand of the molding machine. Can be specified.

Or, suppose that the kneading machine stopped abnormally due to overload. There may be abnormalities in the kneader itself, such as an abnormality in the kneader's muller wheel, an abnormality in the motor system of the muller wheel, etc., but there are also cases where the moisture control before the kneading machine is abnormal. is there. That is, moisture control before the kneading machine, that is, correct sand moisture cannot be measured by a moisture sensor in the pre-molding sand property measuring instrument 12 described later, and water injection in the kneading machine becomes excessive, resulting in overload. There is also. Therefore, it is possible to determine whether or not the moisture measurement value, sand temperature, and atmospheric temperature in moisture control are abnormal.

As in the above example, there may be a case where an abnormality occurs in the device due to an abnormality in other equipment. Therefore, in the system 100 that detects the cause of the abnormality of a plurality of devices, the information obtained by each of the sampling PLCs 102 is sent to the abnormality determination computer 108. When the abnormality determination computer 108 determines an abnormality of a certain device, the cause is searched for including the information of surrounding devices, and the true cause of the abnormality is specified. Thus, according to the system 100, the true cause of the abnormality of a certain apparatus in the facility comprised of a plurality of apparatuses such as a casting facility can be specified.

Next, the configuration of the casting equipment 1 will be described with reference to FIGS. FIG. 2 is a plan view showing the configuration of the casting equipment, and FIG. 3 is an enlarged view of part A in 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. 2, 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. 4 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 sensor 39 that detects that the mold M is conveyed. The mold position 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 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. 2, the mold transport unit 30 includes a gas drilling device 40, an upper / 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. Sand is used for a mold by removing iron powder, a binder and the like mixed with a sand recovery 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 charging unit 60 has a plurality of alloy material hoppers 62 and charges one or more types of alloy materials into the processing 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 charging unit 60 has a measuring instrument (not shown) and a timer (not shown) for measuring the weight of the alloy material charged 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. 5, 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 cart 52 with an empty replacement function may include a ladle position detection sensor 59 (see FIG. 3) 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. 6, the molten metal transport unit 50 is different from the empty replacement position P4 in which the molten metal is replaced from the processing ladle L1 (strictly speaking, the same sign is used for convenience, although it is different from the empty replacement position P4 of the processing ladle L1. ), 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. Even if a pouring ladle transport mechanism 58 that transports the pouring ladle L2 in a direction orthogonal to the traveling direction of the pouring ladle transport carriage 54 is installed between the transfer position P5 and the pouring machine 72. Good. 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 an encoder 523, 543 installed in the hot water receiving cart 52 with the air replacement function shown in FIG. 5 or the pouring ladle transport cart 54 shown in FIG. 6, 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. 7, the pouring unit 70 has a pouring machine 72 for pouring from the pouring ladle L2 into the mold M. 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. 7, the pouring unit 70 preferably has 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. 8, the casting facility 1 includes a casting facility management computer 91 that manages the entire casting facility 1, and each unit includes a control device, that is, the molding unit 10 includes a molding unit control device 11. The mold conveyance unit 30 includes a mold conveyance unit 31, the molten metal conveyance unit 50 includes a molten metal conveyance unit control device 51, and the pouring unit 70 includes a pouring unit control device 71. 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 device 71 may be installed on the pouring machine carriage 720 as shown in FIG. 7, 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.

Each device includes a sampling PLC 102. Depending on the apparatus, the sampling PLC 102 may not be provided. The casting facility 1 may further include an abnormality determination computer 108. Alternatively, each of the molding unit control device 11, the mold transport unit 31, the molten metal transport unit control device 51, the alloy material charging unit control device 61, and the pouring unit control device 71 may have the function of the abnormality determination computer 108. Alternatively, the casting equipment management computer 91 may have the function of the abnormality determination computer 108.

Next, a casting method and a 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. 9, every time the mold transport unit control device 31 transports the mold, the mold position 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 L1 can be lowered | hung, and it can move to the position close | similar to 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 includes the ladle serial number of the processing ladle L1 and the second one. 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. 10, the molten metal transport unit 50 has a ladle position at the pouring position P1, a hot water receiving position P2, a reaction position P3, an empty replacement position P4, and a 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. 11 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. 2 will be described with reference to FIGS. 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. Moreover, the position of the pouring ladle L2 is detected by the encoder 843.

As shown in FIG. 14, 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.

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.

In the above-described embodiment, molding data is collected while the mold is transported by the mold transport unit control device 31, and when a malfunction occurs, the malfunction information is associated with the mold serial number by the mold transport apparatus control unit 31, and the casting equipment It transmits to the management computer 91. Therefore, the mold conveyance device control unit 31 may function as the abnormality determination computer 108 and specify the true cause of the malfunction. The mold conveyance device control unit 31 stores the operating status of other devices that cause an abnormality in a certain device, along with information on malfunctions, the pusher 38, the gas drilling device 40, the sand cutter 42, the gate cutter 43, etc. Data from the apparatus may be received from the mold transport apparatus control unit 31, and the true cause of the malfunction may be specified by comparing with the stored operation status.

Similarly, the molding unit control device 11, the molten metal transport unit control device 51, the alloy material charging unit control device 61, or the pouring unit control device 71 may function as the abnormality determination computer 108. These control devices 11, 51, 61, 71 may store the operating status of other devices that cause an abnormality in a certain device, receive data from each device, and identify the true cause of the malfunction.

Further, the casting equipment management computer 91 may function as the abnormality determination computer 108. That is, the casting facility management computer 91 stores the operating status of other devices that cause an abnormality in a certain device, and the molding unit control device 11, the mold transport device control unit 31, the molten metal transport unit control device 51, and the alloy material input unit control. The true cause of the malfunction may be specified based on the data of each device sent via the device 61 or the pouring unit control device 71.

According to the casting facilities 1 and 2, the information about the mold M is associated with the mold sequence number issued for each mold, and the information about the molten metal is associated with the ladle sequence number for each ladle. When the molten metal is poured into the mold M by the pouring machine 72, the mold serial number of the mold M at the pouring position P6 is associated with the ladle serial number of the poured ladle L2. 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. 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. Based on the cause of the abnormality determined by the abnormality determination computer, the operator can identify a product that may have a defect based on the information managed in this way, and the product in which the defect has occurred can enter the downstream process. It can be prevented from being sent.

Separately from the mold unit control device 11, the mold transport device control unit 31, the molten metal transport unit control device 51, the alloy material charging unit control device 61, the pouring unit control device 71, or the casting equipment management computer 91, the sampling PLC 102 or an abnormality A determination computer 108 may be provided to identify the cause of the abnormality of the apparatus.

The casting facilities 1 and 2 include a sand processing unit 80 that adjusts the molding sand supplied to the molding unit to a property suitable for molding, and a core molding unit (or core unit) that molds the core placed in the mold. 82 may be further provided. In addition, the sand processing unit 80 or the core molding unit 82 may be installed in a building different from the casting facilities 1 and 2, and in that case, it is also a part of the casting facilities 1 and 2. . Mold sand adjusted by the sand processing unit 80 is sent to the molding unit 10 and molded into a mold by the molding apparatus 14. The core molded by the core molding unit 82 is sent to the core setter 45 of the mold transport unit 30 and set in the mold.

The abnormality determination computer 108 or the casting equipment management computer 91 is used to determine whether the castings cast in the casting equipment 1 and 2 are defective, the molding unit 10, the mold transport unit 30, the molten metal transport unit 50, the alloy material charging unit 60, and the molten metal. It is preferable to store the relationship between causes or defects in the unit 70, the sand processing unit 80, and the core unit 82 as a matrix database. FIG. 15 schematically shows an example of the matrix database. In the example shown in FIG. 15, guilloche (dimensions caused by the upper and lower mold deviations generated on the divided surface of the casting), sand biting (intrusion of lump or plate-like sand intervening near the casting surface), noro biting (slag is The casting defect that flows into the mold during pouring and is caught, which remains in the product after solidification), shrinkage cavity (cavity with rough inner wall mainly caused by solidification shrinkage of the melt on the surface or inside of the casting), poor hot water (Defects caused by solidification before the molten metal fills the mold), gas (large and small bubbles generated inside the casting produced by entraining air, gas generated from the mold or gas released from the molten metal during casting, etc. Holes) and dents (defects caused by bumping the surface when the mold is separated) are regarded as defective castings. Sand processing unit, molding unit, core unit, pouring unit, cooling zone of mold transport unit, and mold transport Six representative processing point of the knit of the post-processing apparatus (mold disassembling device) is set to its defective causative device.

For example, the cause of the occurrence of guitch is considered to be a malfunction of the mold alignment / mold transfer device 47, a malfunction of the mold transfer lane, etc. Data relating the mold transport lane is stored. Therefore, when a guilloche occurs in the casting, the abnormality determination computer 108 or the casting equipment management computer 91 performs control so as to check the operating conditions of the mold alignment / mold transfer device 47 and the mold conveyance lane in the molding unit 10.

As a result, when the operating status of the device causing the problem is found, the operation of the device is adjusted to eliminate the problem. For example, when the transport speed of the mold transport lane is too high and guilloche occurs, the transport speed of the mold transport lane is decreased. These adjustments can be made by the molding unit control device 11, the mold transport unit control device 31, and the molten metal transport unit control device 51 that have received information from the abnormality determination computer 108 or the casting equipment management computer 91.

As described above, by using the matrix database that associates casting defects with processing points or equipment defects, it becomes possible to quickly and reliably identify the equipment that causes casting defects. Furthermore, the cause of the casting defect can be eliminated by adjusting the operation of the device causing the problem by the control device of each unit.

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 37 Mold position detection encoder 38 Mold feed pusher (conveyance mechanism)
39 Mold position 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 machine 47 Mold alignment / mold transfer device 48 Mold dispersal device 50 Molten metal conveying unit 51 Molten metal transfer unit controller 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 charging unit 61 Alloy material charging Unit controller (alloy material input controller)
62 Alloy material hopper 70 Pouring unit (molten transfer unit)
71 Pouring unit control device 72 Pouring machine 76 Test piece (TP) sampling unit 80 Sand processing unit 82 Core molding unit (core unit)
91 Casting Equipment Management Computer 100 System 102 for Detecting Causes of Abnormalities in Multiple Equipments Constructing Casting Equipment 102 Sampling PLC
104 Switching Hub 106 Wireless Communication Device 108 Abnormality Determination Computer 520 Traveling Cart 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 (13)

1. A system for detecting a cause of an abnormality in a plurality of apparatuses constituting a casting facility for forming a mold, transporting the mold to a pouring position, and pouring the mold to obtain a casting,
   A sampling PLC that monitors and stores information relating to the operation of at least one of the plurality of devices;
   An abnormality determination computer that receives information related to operation of the plurality of devices from the plurality of sampling PLCs, determines abnormality of the device from information related to operation of the device, and causes the abnormality of the device An abnormality determination computer storing operation states of the plurality of devices,
   When the abnormality of the device is determined from the information regarding the operation of at least one of the plurality of devices, the abnormality is determined from the received information regarding the operation of the plurality of devices based on the stored operation state of the plurality of devices. Identify the operating conditions that cause
   system.
2. The plurality of devices have an ammeter for measuring a current value for operating the device or a voltmeter for measuring a voltage value,
   The sampling PLC monitors the current value or the voltage value as information related to the operation.
   The system of claim 1.
3. The plurality of devices include a sound level meter that measures noise of the device or a vibrometer that measures vibration.
   The sampling PLC monitors the noise or the vibration as information related to the operation.
   The system of claim 1.
4. The sampling PLC and the abnormality determination computer are connected by a LAN via a switching hub.
   The system of claim 1.
5. 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 the molding plan data from the casting equipment management computer, controls the molding device to mold the mold with the molding plan corresponding to the molding plan data, and for the 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 control device 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 in accordance with the pouring plan corresponding to the pouring plan data corresponding to the casting serial number, and the ladle serial number of the poured pouring ladle is the mold. Sending to the casting equipment management computer in association with the serial number,
   The system according to any one of claims 1 to 4.
6. The molding unit control device also serves as the abnormality determination computer;
   The system according to claim 5.
7. The mold transport unit control device also serves as the abnormality determination computer,
   The system according to claim 5.
8. The pouring unit control device also serves as the abnormality determination computer;
   The system according to claim 5.
9. The casting equipment management computer also serves as the abnormality determination computer;
   The system according to claim 5.
10. The casting equipment is
    A sand treatment unit for adjusting the molding sand supplied to the molding unit to a property suitable for molding;
    A core molding unit for molding a core to be placed in the mold;
    Further comprising
    The abnormality determination computer stores a defect state of a casting cast by the casting equipment and a cause of the defect in the unit in a matrix database, and obtains data of the matrix database from information on operation of the at least one apparatus. To determine the malfunction of the device,
    The system according to claim 5.
11. The matrix database associates the defective state of the casting with processing points divided into six processing points of sand processing, molding, core, pouring, cooling, and post-processing. The system of claim 10.
12. The casting equipment is
    Based on the determined defect, the apparatus further includes an adjustment unit that adjusts the apparatus that causes the defect in order to eliminate the defect.
    The system according to claim 10.
13. The system according to claim 12, wherein the adjusting means is any one of the molding unit control device, a mold transport unit control device, and a pouring unit control device.
    

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