CN115055671A - Factory for producing large-tonnage castings - Google Patents

Abstract

A factory for producing large-tonnage castings belongs to the technical field of casting and is used for solving the problems of poor production environment and large potential safety hazard of a casting factory, the whole plane layout of the factory is rectangular, a channel is arranged in the middle of the length direction, the factory is divided into a first area and a second area by the channel, and operation areas of all processes are arranged in the first area and the second area; the operation area of each procedure comprises a forming area, a drying area, an assembly area, a smelting area, a casting area, a box beating area and a post-treatment area; the forming area is arranged in the first area and the second area in a spanning mode and is arranged at one end of a rectangular factory; a drying zone, a smelting zone and a casting zone are sequentially arranged in the first zone towards the direction far away from the forming zone; and an assembly area, a box beating area and a post-processing area are sequentially arranged in the second area towards the direction far away from the forming area. The safe, green and efficient operation of the casting plant is realized.

Description

Factory for producing large-tonnage castings

Technical Field

The invention relates to the technical field of casting, in particular to a factory for casting.

Background

The national requirements on environmental protection and safety of the manufacturing industry are continuously improved, and the industrial informatization is continuously developed, so that how to develop the traditional casting industry to green, safe and informatization is the key point of industry attention for the traditional casting industry with poor production environment and large potential safety hazard, which has great influence on the health and life safety of operating personnel, and the current situation of the traditional casting industry is as follows:

1) the logistics between the working procedures is carried out by means of traveling cranes, and the problems that the traveling cranes have serious interference and the hoisted objects slide in the operation space, so that great hidden danger exists on the safety of operators; more than 70% of accidents in casting plants are caused by crane lifting;

2) in the processes of molding, core making and casting, dust and toxic gas in the air of an operation space of an operator seriously exceed standards, and the health of the operator is seriously threatened;

3) the operation is mainly manual operation of matching the mould by manual operation of operators, the heavy labor intensity of the operators is high, the informatization within each process and among the processes is poor, the information transmission is delayed, and the like;

4) the core shooter, the molding machine and the sand mulling and quicksand equipment are all large, so that the occupied area of a casting factory is large.

Disclosure of Invention

In view of the problems of high potential safety hazard and poor working environment of the traditional casting factory, a factory for producing large-tonnage castings is needed, the factory for producing the large-tonnage castings realizes no traveling crane, low dust and low toxic gas, and realizes high automation between and in the process.

A factory for producing large-tonnage castings is characterized in that the whole plane layout of the factory is rectangular, a channel is arranged in the middle of the factory in the length direction, the channel divides the factory into a first area and a second area, and operation areas of all procedures are arranged in the first area and the second area; the operation area of each procedure comprises a forming area, a drying area, an assembling area, a smelting area, a casting area, a box beating area and a post-processing area, wherein the forming area is used for producing or manufacturing sand cores and/or sand molds; the drying area is used for drying the sand core or the sand mold, and can also be used for drying the sand core or the sand mold coated with the coating; the assembly area is used for assembling or matching the sand mold and/or the sand core into a core bag with a complete casting structure cavity to be cast; the smelting zone is used for smelting molten metal for casting the casting; the casting area is used for casting molten metal into the core package, and a casting is formed after the molten metal is cooled; the boxing zone is used for taking the casting out of the core bag; the aftertreatment region is configured to clean and/or reprocess the casting. The forming area is arranged at one end of the rectangular factory in the width direction, namely the forming area is arranged at one end of the first area and the second area in a spanning mode; the drying zone is arranged on one side of the first zone close to the forming zone, and the assembling zone is arranged on one side of the second zone close to the forming zone; in order to realize the shortest sequence change of the semi-finished products between the working procedures and the minimum production takt, the drying area and the assembling area are arranged and arranged close to the forming area; the smelting zone is arranged in the first area and is adjacent to the drying zone, and the casting zone is arranged close to the smelting zone, so that the transfer distance of molten metal qualified for smelting is shortest, the casting efficiency is improved, and the phenomenon that the metal casting temperature exceeds the range due to long-distance or long-time molten metal transfer is avoided; a boxing area is arranged in the second area and is adjacent to the assembling area; the spatial position occupied by the smelting zone corresponds to the assembling zone, and the casting zone corresponds to the boxing zone, so that the transfer distance of the casting blank is shortest, and the transfer efficiency is improved; the post-treatment area is arranged in the second area and is adjacent to the box beating area, so that the post-treatment area is adjacent to the box beating area, and the transfer of the castings in the shortest distance can be realized; through the reasonable arrangement of the corresponding operation areas, the operation efficiency is higher, the production takt is shorter, and the efficient and smooth operation of production operation is realized.

Preferably, the forming area adopts a 3DP printing process, and is provided with a plurality of 3DP printing devices with different specifications for printing sand cores and/or sand molds.

Preferably, the molding zone is further provided with a centralized sand supply system, the centralized sand supply system is arranged at one end or one corner of the molding zone, the centralized sand supply system adopts the pipeline for conveying sand, thereby avoiding dust from diffusing into the environment, reducing the content of dust in the operating environment and avoiding the physical damage to operators, conveying the raw materials required by the 3DP printing equipment to the material shortage station (namely the hopper of the material shortage 3DP printing equipment) through the pipeline, the centralized sand supply system adopts a mode of mixing and supplying the fresh sand and the reclaimed sand, namely, the fresh sand and the reclaimed sand are uniformly mixed according to a certain use proportion and then are supplied to a station needing raw materials (namely molding sand), thereby improving the reutilization rate and the reutilization rate of raw materials, and the factory for producing large-tonnage castings becomes a green casting factory by using the reclaimed sand and the pipeline sand transportation. By arranging the centralized sand supply system in this way, the sand conveying is most convenient and rapid, and the production efficiency is highest.

Preferably, the centralized sand supply system is also provided with a thermal regeneration device, and the used sand from the boxing area can become reusable regenerated sand after passing through the thermal regeneration device.

Preferably, the factory for producing large-tonnage castings is further provided with a centralized liquid supply system, the centralized liquid supply system is arranged at one end, the middle part or one corner of the forming area and used for supplying liquid materials to 3DP printing equipment, and the liquid materials are conveyed through a pipeline, so that peculiar smell of the liquid materials is prevented from volatilizing into the operating environment, the pollution of the operating environment gas is reduced, the environmental safety of operating personnel is improved, and the physical health of the operating personnel is ensured. By arranging the centralized sand supply system in this way, the sand conveying is most convenient and rapid, and the production efficiency is highest.

Preferably, the molding area is also provided with a sand removing room, and the sand removing room is arranged adjacent to the centralized sand supply system, so that the sand recovery path is reduced, and the production energy consumption is reduced; the sand cleaning room is used for cleaning loose sand on the surface of a sand core or a sand mould and/or in a cavity in a sand blowing mode, dust can be prevented from diffusing to other operation areas in the sand cleaning process, and the environmental safety of the other operation areas is protected.

Preferably, the drying zone is further provided with an application booth for applying sand cores or sand moulds, the application booth avoiding contamination of other areas with application liquid, the application booth being located at the end of the drying zone remote from the tunnel, so that the transport distance of the sand cores or sand moulds from the forming zone is minimized.

Preferably, the drying area is provided with a drying device, a hot air drying technology or a microwave drying technology is adopted, the drying device is a hot air drying device or a microwave drying device, and the hot air drying device or the microwave drying device is arranged at one end of the drying area close to the channel, so that the transfer distance of the sand core or the sand mold to be transferred to the assembly area is shortest, and the production efficiency is improved; and (3) drying the sand core or the sand mold after being coated or before being coated by the microwave drying equipment, so that the next process can be carried out.

Preferably, a mill for producing the large-tonnage foundry goods still is equipped with AGV transfer device, AGV transfer device is used for transporting the work piece in each operation interval, AGV transfer device is through received instruction, and the work piece that will wait to transport transports next process from current process to realize the automatic circulation of process room work piece, promoted the automation level and the digital level of mill.

As a supplement to this solution, the plant for producing large tonnage castings further comprises a finished product area, which is disposed in the second area and behind the post-treatment area, to facilitate transfer of the processed qualified castings to the finished product area.

The technical scheme of the invention has the beneficial effects that: the shortest transfer distance between the working procedures is realized by reasonably arranging the positions of all the working areas, and the operation efficiency of a factory is improved; by setting the forming area of the 3DP printing process, the risk that original quicksand and dust and chemical reagents are diffused into a working environment in the forming process is avoided, and the safety of the working space of operators is improved; based on the numerical control of the 3DP printing equipment, the digitization and the intellectualization of a factory can be improved, and the production adjustment speed and the flexible production capacity of the factory are improved.

Drawings

FIG. 1 is a schematic view of the present invention;

FIG. 2 is a schematic diagram of a plant for producing large tonnage iron castings;

FIG. 3 is a schematic diagram of a plant for producing large tonnage steel castings.

Detailed Description

In order to more clearly illustrate the technical solutions of the present invention, the technical solutions of the present invention are described in detail with reference to the accompanying drawings, and it is obvious that the following descriptions are some exemplary embodiments of the present invention, and it is obvious for those skilled in the art that other solutions can be obtained according to the embodiments without creative efforts.

A factory for producing large-tonnage castings is characterized in that the whole plane layout of the factory is rectangular, a channel is arranged in the middle of the factory in the length direction, the channel divides the factory into a first area and a second area, and operation areas of all procedures are arranged in the first area and the second area; the operation area of each procedure comprises a forming area, a drying area, an assembling area, a smelting area, a casting area, a box beating area and a post-processing area, wherein the forming area is arranged on the first area and the second area in a crossing manner and is arranged at one end of the width direction of the factory, namely, the forming area occupies one end of the width direction of the factory; on the first area, in the direction away from the forming area, a drying area, a smelting area, a casting area and other operation areas are arranged in sequence; and on the second area, in the direction away from the forming area gradually, an assembly area, a box beating area, a post-processing area and other operation areas are arranged in sequence. By arranging the operation areas in this way, the distance of workpiece transfer between the operation areas is minimized, the production takt is shortest, the production efficiency is highest, and the production mode of less transfer and high efficiency of large-tonnage castings is realized.

The first embodiment is as follows:

the technical scheme of the invention is elaborated by taking a large-tonnage iron casting factory with total energy of 40000 tons of iron castings as an example.

A factory for producing large-tonnage iron castings at least comprises a forming area, a drying area, an assembly area, a smelting area, a casting area, a box beating area and a post-treatment area; in order to facilitate production, a factory is divided into two parts in the length direction, namely a first area (the left side of fig. 2) and a second area (the right side of fig. 2), the forming area is arranged at the end of one end of the factory in the width direction and spans the first area and the second area, the forming area is used for producing and manufacturing sand cores and/or sand molds, and the sand cores and/or the sand molds can be assembled into castings with specific cavity structures through the assembly rules of a casting process; the forming area is provided with a plurality of 3DP printing devices, and the 3DP printing devices print corresponding sand cores or sand molds according to a set program; a drying zone, a smelting zone, a casting zone and the like are sequentially arranged in the first zone in the direction far away from the forming zone; and an assembly area, a box beating area and a post-processing area are sequentially arranged in the second area in the direction far away from the forming area. After passing through the operation areas, required castings can be produced according to a casting process. The drying area is used for drying the sand core or the sand mold from the forming area, the coating operation area is further arranged in the drying area, and the coated sand core or sand mold can be dried again in the drying area, so that the coating and drying of the sand mold or the sand core are completed for subsequent assembly. The assembly area is used for assembling the sand core or the sand mold into a core package with a complete casting type strength, and the core package can be used for casting a casting. And the smelting zone is provided with a smelting furnace for smelting molten metal for casting, the molten metal is transferred to a casting ladle, and the molten metal is cast into the core package from the casting ladle so as to form a casting. The casting area is placed and is buried case or the good core package of treating the casting of centre gripping, and the core package after the casting need be in the casting area waits for the cooling, and the degree that can make the case is reached to the metal liquid condensation, will bury the case or the good core package of centre gripping is transported and is made the case the district. The boxing zone is provided with a boxing device, such as a vibration shakeout machine and the like, and can shake off a core bag with a cooled casting inside the casting, so that the casting is obtained. The post-treatment area is provided with a rough cleaning room and a fine cleaning room, wherein the rough cleaning is to place the casting with the casting head cut off in shot blasting equipment, perform shot blasting on the casting, and clean sand inclusion, fine batch seams and the like on the surface of the casting; the fine cleaning is to polish the casting by manpower or a robot so as to clean larger surface problems, batch seams and the like.

As an optimization of this embodiment, before the sand core or the sand mold enters the drying area, the sand core or the sand mold taken out from the 3DP printing device needs to be subjected to a sand cleaning process, the sand cleaning process is arranged in a sand cleaning room, a sand cleaning device is arranged in the sand cleaning room, and may be a high-pressure air gun, an operator manually cleans the sand core or the sand mold, or may be a suspended rotatable air knife, and the air knife can clean the loose sand on the surface of the sand core or the sand mold and in the cavity. The drying area is provided with microwave drying equipment, and the sand core or the sand mold can be dried in a microwave drying mode, so that the sand core or the sand mold drying efficiency and quality are improved.

As an optimization of this embodiment, the knockout area is further provided with a dead head cutting room, and a cutting device is arranged in the dead head cutting room, so as to conveniently cut off a casting system and a dead head on the casting after knockout and shakeout, thereby obtaining a casting blank.

As an optimization of this embodiment, in the post-treatment area, a heat treatment room may be further provided to perform heat treatment on the castings to be subjected to heat treatment, so as to meet the corresponding physicochemical requirements.

As an optimization of this embodiment, the shaping district still is equipped with and concentrates the sand supply system and concentrate the liquid supply system, concentrate the sand supply system be used for the 3DP equipment provides the molding sand, just it still is equipped with hot regenerating unit in the sand supply system to concentrate, through hot regenerating unit handles the reclaimed sand that can reuse for the method that the old sand from the district of forging the box passes through hot regeneration, will reclaimed sand mixes the back with new molding sand according to usable proportion, carries on lacking the 3DP equipment of molding sand, concentrate the sand supply system and adopt the pipe-line transportation molding sand for the molding sand has avoided exposing in the environment and has caused the dust to the environment unable, has avoided the dust to fly to the environment. Concentrate the liquid supply system be used for to the 3DP equipment provides the liquid material, the liquid material is used for printing the profile of waiting to produce sand mould or psammitolite, the liquid material passes through the pipeline and gives the equipment of needs to realize concentrating the confession liquid, avoided adopting the removal transfer device to transport 3DP printing apparatus that needs and the reinforced in-process powder diffusion of raw materials storehouse with liquid material and molding sand, float and the liquid material volatilizees to the operational environment in, thereby promoted operational environment security, promoted the greenness of mill.

As an optimization of the embodiment, in order to improve the production efficiency of a factory, trackless AGV transfer vehicles are adopted for transferring workpieces in each operation interval and each operation area, so that the condition that the travelling vehicles are arranged at the top of the factory is avoided, the condition that a plurality of travelling vehicles wait and avoid in the operation process is avoided, and the operation efficiency of the factory is improved.

As an optimization of the embodiment, the factory for producing the large-tonnage iron castings is further provided with a paint spraying booth, the paint spraying booth is arranged behind the post-treatment area, the paint spraying booth is arranged in the direction, far away from the forming area, of the second area and next to the post-treatment area, and the paint spraying booth is used for spraying paint on the castings qualified in post-treatment, so that the surface oxidation of the castings is avoided, and a certain protection effect is achieved.

As an optimization of this embodiment, the plant for producing large tonnage iron castings is further provided with a finishing booth, which is provided with a second area immediately after the painting booth in a direction away from the forming area, so as to transfer qualified castings to the finishing booth for shipment.

The second embodiment:

the technical scheme of the invention is elaborated by taking a large-tonnage steel casting factory with the total energy of 10000 tons of steel castings as an example.

A factory for producing large-tonnage steel castings at least comprises a forming area, a drying area, an assembly area, a smelting area, a casting area, a box beating area and a post-treatment area; for convenience of production, a factory is divided into two parts in the length direction, namely a first area (the left side of FIG. 2) and a second area (the right side of FIG. 2); the second area is provided with the forming area, the smelting area and the post-treatment area from one end to the other end in sequence; and a drying zone, an assembling zone, a box beating zone, a casting zone and a post-processing zone are sequentially arranged in the first zone from one end corresponding to the forming zone. The forming zone, the drying zone, the box beating zone and the smelting zone are arranged at one end which is relatively concentrated, so that the direct influence of noise and dust of the post-treatment zone on other operation areas is avoided. Preferably, the connection position of the post-treatment zone and the casting zone arranged in the first zone is equivalent to that of the post-treatment zone and the smelting zone arranged in the second zone, namely the post-treatment zone and the smelting zone are positioned at the same vertical position, so that the post-treatment zone is positioned at the same section position, and the mutual interference between operation zones is avoided.

As a supplement to this embodiment, the post-treatment zone provided in the first zone is provided with a shot blasting room, a heat treatment room, a relief grinding room, a post-welding heat treatment room, a paint spraying room, etc.; the shot blasting chamber is used for roughly cleaning the boxed castings, namely placing the castings in shot blasting equipment, and performing shot blasting on the surfaces of the castings and the cavity so as to achieve the purpose of cleaning the surface sand; the heat treatment chamber is used for carrying out post-treatment on the steel casting so as to enable the material of the steel casting to meet the set requirement; the relief grinding room is used for manually or robotically cleaning batch seams on the surface of the casting or in the cavity by adopting a grinding wheel; aiming at defects generated in casting and post-treatment of the steel casting, such as cracks, slag inclusion cleaning gaps and the like, after welding treatment, in order to enable the welded part and the body to have the same mechanical property, secondary heat treatment needs to be carried out on the steel casting if necessary; in order to avoid corrosion of qualified steel castings by the environment, the surfaces of the steel castings can be painted, and the painting operation is arranged in the painting room.

As a supplement to this embodiment, the post-treatment area disposed in the second area is provided with a gouging room and a detection room for gouging the heat-treated castings, so as to meet the surface quality requirements of the castings; the detection room is used for detecting various properties of the casting, such as density detection of the casting and the like.

As another supplement to this embodiment, the factory for producing large tonnage steel castings is further provided with a finished product room, which is disposed in the second area adjacent to the inspection room and at the other end of the second area opposite to the molding area, for placing the castings to be delivered.

The above embodiment is only a description of a typical application of the technical solution of the present invention, and may be reasonably expanded without creative efforts.

Claims (10)

1. A factory for producing large-tonnage castings is characterized in that the whole plane layout of the factory is rectangular, a channel is arranged in the middle of the factory in the length direction, the channel divides the factory into a first area and a second area, and operation areas of all processes are arranged in the first area and the second area; the operation area of each procedure comprises a forming area, a drying area, an assembly area, a smelting area, a casting area, a box beating area and a post-treatment area;

the forming area is arranged in the first area and the second area in a spanning mode and is arranged at one end of a rectangular factory; a drying zone, a smelting zone and a casting zone are sequentially arranged in the first zone towards the direction far away from the forming zone;

and an assembly area, a box beating area and a post-processing area are sequentially arranged in the second area towards the direction far away from the forming area.

2. The plant for the production of large tonnage castings according to claim 1, characterized in that said forming section employs a 3DP printing process, provided with a plurality of 3DP printing devices of different specifications.

3. The plant for the production of large tonnage castings according to claim 2, characterized in that said molding zone is further provided with a centralized sand supply system using pipes to supply molding sand to a plurality of said 3DP printing devices.

4. The plant for the production of large tonnage castings according to claim 2, wherein said forming section is further provided with a centralized liquid supply system using piping to supply liquid to a plurality of said 3DP printing devices.

5. A plant for the production of large tonnage castings according to claim 3, characterized in that said molding section is further provided with a thermal reclamation apparatus which regenerates used sand from the boxing section into usable reclaimed sand.

6. A factory for producing large tonnage castings according to claim 2, wherein said molding section is further provided with a sand removal booth, said sand removal booth cleaning loose sand from the surface of the sand core or sand mold or mold cavity by means of sand blowing.

7. A plant for the production of large tonnage castings according to claim 1, characterized in that said drying section is provided with an application booth for the application of sand cores or molds.

8. A plant for the production of large tonnage castings according to claim 7, wherein said drying section is further provided with a drying device for drying the sand cores or molds by hot air or microwave drying.

9. The plant for producing large tonnage castings according to claim 1, further comprising AGV transfer means for transferring the workpieces between each work section.

10. A factory for producing large-tonnage castings is characterized in that the whole plane layout of the factory is rectangular, a channel is arranged in the middle of the factory in the length direction, the channel divides the factory into a first area and a second area, and operation areas of all processes are arranged in the first area and the second area; the operation area of each procedure comprises a forming area, a drying area, an assembly area, a smelting area, a casting area, a box beating area and a post-treatment area;

a forming zone, a smelting zone and a post-treatment zone are sequentially arranged in the second area from one end to the other end;

and a drying zone, an assembling zone, a box beating zone, a casting zone and a post-processing zone are sequentially arranged in the first zone from one end corresponding to the forming zone.

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