CN1203130A - Electroslag casting shaper for continuous making of crankshafts and shaft parts - Google Patents

Electroslag casting shaper for continuous making of crankshafts and shaft parts Download PDF

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Publication number
CN1203130A
CN1203130A CN 98101898 CN98101898A CN1203130A CN 1203130 A CN1203130 A CN 1203130A CN 98101898 CN98101898 CN 98101898 CN 98101898 A CN98101898 A CN 98101898A CN 1203130 A CN1203130 A CN 1203130A
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establish
consutrode
hearth electrode
water
mould
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CN1051036C (en
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陈中兴
叶正光
刘延龄
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Abstract

A nearly-net shaping electroslag casting apparatus for crankshafts and shaft-type workpieces is composed of main body with circular stand, automatic feeding mechanism of consumable electrode, alternative-work double electrodes, modular die set, manipulator for taking workpieces, circulating cooling water system and computer control system. Under the control of computer, the four main parameters about electricity, slag, water and mould are automatically controlled for obtaining repeatable temp. field and accurately judging the boundary coordinates and the right moment when crank is formed. Its advantages are high safety, high productivity and high consistence of products.

Description

The electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle and axle class part
The invention belongs to when metal is carried out refining, finish the equipment of the whole fusion cast process of product, the electroslag smelting casting near-net-shape equipment of particularly a kind of bent axle of working continuously and axle class part.
In various axle class parts, bent axle is a kind of complex contour, the demanding part of mechanical performance.At present, industrial production is extensively adopting the full fiber die-forging forming method of spheroidal graphite cast-iron casting or steel to make various crank shaft blanks.Casting, to forge investment in machinery and equipment big, and material, energy resource consumption are many, and environmental pollution is heavy, and the congenital hidden danger of product is difficult to eliminate.In recent years, electric slag casting crankshaft one step integral forming method and apparatus occurs, for example, used Chinese patent " 86108925 improved one-shot forming bent axle electroslag casting equipment " can produce the electric slag casting crankshaft blank that inherent quality is not less than the die forging bent axle.Overcome casting significantly, forged the defective that product is prone to.Prior art equipment is made up of mould bases pillar, die body, feed mechanism, consutrode, hearth electrode, water-cooled primary crystallization device, utilize the rotation of water-cooled primary crystallization device and die body, slippage, when progressively forming the shape cavity shape, continuous fusion-cast constantly changes the shape cavity shape simultaneously, reaches the composite deformation moulding, when the rotation of water-cooled primary crystallization device and die body, slippage change the shape cavity shape and finish, crank shaft blank is Integratively formed to be finished.But, when prior art equipment makes the crank throw moulding by operating sliding block manually, by rule of thumb, can not ensure safety accident-proneness; Product blank periphery slag crust is uneven, causes the size discreteness big, can not directly integrate with back road machined; Monomer intercropping formula production efficiency is low, and material, the energy, man-hour are wasted big, and when multiple devices were produced in enormous quantities, mould took investment greatly.Mould is not only ruined in the die sinking of chiso-mallet thick stick sled formula, and civilization degree is poor.
The objective of the invention is to overcome the deficiency of prior art equipment, solution existing equipment poor stability, the problem that efficient is low, the product size discreteness is big, adopt electricity, slag, water, the mould four big parameters quantitatively controlled in the production process, obtain reproducible crystallization temperature field, accurately judge interface coordinate and crank throw moulding opportunity, to reach the continuous fusion-cast operation, the product size near-net-shape, ensure production safety, raise the efficiency and homogeneity of product.
Purpose of the present invention can be achieved through the following technical solutions, the electroslag smelting casting near-net-shape equipment of a kind of continuous cropping formula bent axle and axle class part, comprise (1) agent structure system, (2) feeding system, (3) power-supply system, (4) mould and operational system, (5) get the fortune workpiece system, (6) recirculating cooling water system, (7) control system, its concrete structure structure is:
(1) agent structure is made up of ring bench-type support, lifting platform, last turntable, following turntable and four column bearing supports, support is ring platform shape hollow slab type structure, corresponding each die unit of periphery is established transparent discharge casing, establish 2-4 hydraulic lifting column on the support, lifting platform is established on hydraulic lifting column top, and turntable is established in the lifting platform below, and the upper surface of support is board-like annular base station, centering is provided with down turntable below the annular base station, four column bearing supports is set below the following turntable.
(2) feeding system, send the structure of meeting sb. at the airport, consutrode automatic feed mechanism and mend slag mechanism with the constant temperature automated procedure of its synchronous operation and form by consutrode, top and side that consutrode send the structure of meeting sb. at the airport to be arranged on the consutrode automatic feed mechanism, the consutrode automatic feed mechanism is arranged on middle position on the lifting platform, and two constant temperature automated procedures are mended the suspension of slag mechanism and are arranged on the turntable below.
(3) power-supply system, Double bottom electrode, power transformer by top electrode, alternation are automatically formed, the top electrode insulation is hung and is arranged on consutrode automatic feed mechanism below, on wherein two root posts of four column bearing supports, respectively establish a hearth electrode, each hearth electrode is provided with the follow procedure automatic lifting, stretch out, step up, the mechanism of unclamping, returning.
(4) mould and operational system; carry out each executing agency that the three dimensions program is moved by each die unit in building block system mold system and the assurance mold system; the support that comprises agent structure; lifting platform; last turntable; following turntable; both arms droop manipulator and die sinking machine; last turntable is divided into and its fixing both arms droop manipulator that is connected that hangs; park each die unit of wait work on the anchor ring of base station in regular turn; the die sinking machine is connected on the following turntable; be symmetrical arranged two the hydraulic pressure die sinkings in every limit head on the die sinking machine; a die sinking upper support; locate in running order each layer mould; inboard and die sinking head at the die sinking machine are 90 ° of layouts; if the emery wheel mechanism of two small-sized automatic advance and retreat; be used for hearth electrode alternately before under the driving at turntable down, workpiece upper base electrode clamping zone is removed skull and the grinding shaping is worked.
(5) get the fortune workpiece system; by cutting gun, get the workpiece manipulator, the workpiece conveyer is formed; the four column bearing supports outside below the die sinking machine is established and is got the workpiece manipulator; below each hearth electrode, establish cutter; the pincerlike support of hearth electrode, the insulation blocking of band waterway are arranged between cutter and the hearth electrode, establish conical hopper and conveyer belt composition in the bottom of four column supports and receive the housing apparatus of mucking haulage.
(6) recirculating cooling water system, by the adjustable water supply installation of frequency control constant voltage, flexible pipe net, joint, transparent discharge casing, electrically-controlled valve, each signal transducer and Displaying Meter with form after crystallizer in each die unit is communicated with, transparent discharge casing is arranged in the support of pillar construction.
(7) control system, adopt prior art, (comprising: the minicom work station by supervisory control desk, the power supply power distribution cabinet, drive the variable frequency regulating speed control cabinet of recirculated cooling water, drive the output signal switch board of each executing agency, camera monitor, the print record device, automatically, manual change-over switch is observed each parameter such as voltage during for manual operation, electric current, power, flow, pressure, temperature, feed speed, the amount of feeding, burn-off rate, the fusing amount, mend slag speed, mend the digital instrument of the quantity of slag), the computer input and output interfaces, monitoring signal transducer and each circuit auxiliary equipment of each parameter forms.
Aforesaid consutrode automatic feed mechanism compresses type of belt drive for the spring roller, it by dress initiatively frame and the pressure frame of adorning driven wheels of wheels and holddown spring, screw rod, planning standard spare form idler wheel mechanism, be used to clamp consutrode; Establish vertical Z to motor and stepless time adjustment drive unit on frame, driving rolls mechanisms grip consutrode feeds or withdraws from motion; On the output shaft of motor, establish speed probe at Z, below frame, establish successively horizontal X to, Y to adjusting base, establish X, Y fine setting motor and stepless time adjustment drive unit on the base respectively adjusting, on each fine setting electric machine main shaft, establish speed probe; Between adjustment base and lifting platform, be provided with the pressure sensor supporting, carry out dynamic monitoring, the burn-off rate and the fusing amount of metering consutrode.
Below the consutrode automatic feed mechanism, establish with the body insulation and hang the top electrode that is connected, after consutrode is slidingly matched by the reliable contact with top electrode, insert in the fusing slag bath of mold system forming cavity, mend at the constant temperature automated procedure under the cooperation of slag mechanism, make the distance h of the surface maintenance procedure stipulation of its melting end and metal bath R(t), thus set up normal electroslag smelting casting production process; Consutrode to the needs of guiding mechanism according to fusion-casting process, is adjusted the plane coordinates of temperature field center position by X, Y, guarantees to prevent the safe distance of consutrode and forming cavity wall contact short circuit simultaneously; X, Y, Z to speed, distance, pressure sensor signal circuit be connected with computer interface, the command signal of respectively amplifying after the Computer Processing is passed to each servo-actuating device by output interface.
The consutrode that is arranged on consutrode automatic feed mechanism top and side send the structure of meeting sb. at the airport to be made up of feeding elevator, lifting column, rotating mechanism and two up and down pivoted arm continued access mechanism, establish electronic three-jaw chuck on the upper arm and decide that moment is tightened and tripping-gear, establish hydraulic tongs on the underarm; When needs continued access consutrode, two pivoted arms from elevator, will treat the continued access consutrode clamp, promote, rotate to feeding the consutrode coaxial position after, hydraulic tongs on the underarm unclamps, cause and treat that receiving electrode can rotate freely the guiding support state of slip in pincers, three-jaw chuck clamping at this moment treats that receiving electrode inserts in the guiding awl tube that is contained in above the automatic feed mechanism with lifting column decline; Finish behind the heart, when consutrode that electronic three-jaw chuck continues to connect and the consutrode in the feeding descended synchronously, the threaded together joint was finished the continued access action, and tripping-gear is opened three-jaw chuck thereupon, the playback of two pivoted arm is awaited orders.
The constant temperature automated procedure is mended slag mechanism and is made up of temperature control storage slag case, spiral slag adding machine, support by pressure sensor between temperature control storage slag case and the last turntable, the close consutrode aligning of spiral slag adding machine water conservancy diversion ozzle mold system forming cavity top mouth, symmetrically arranged two benefit slag mechanisms back and forth decide the angle rotation with last turntable evenly injects process benefit slag.The control circuit of pressure sensor and spiral slag adding machine is connected with computer interface.
The building block system mold system can be divided into two kinds of combining forms: a kind of combining form is made up of one group of bottom mould, one group of top layer mould, three layers of phase similar shape chamber, the mould that has a sliding block hydraulic pressure crank throw shaping mechanism; Another kind of combining form is made up of one group of bottom mould, one group of top layer mould, three groups of moulds that have relative floor displacement mechanism.Every layer of mould is one group, split by two die units for every group and form, each die unit is made up of external mold and crystallizer and auxiliary, crystallizer in each die unit can be established one or several, when being combined into a die unit, can be provided with by the zoning in temperature field is corresponding with several crystallizer building block systems.
In continuous cropping formula production process; the program control motion of the three dimensions of each die unit in the mold system be pattern tool operational system (support, lifting platform, both arms droop manipulator and die sinking machine) under the control of computer, co-operating realizes die sinking in regular turn from bottom to up, wait, lifting, rotation, matched moulds, contraposition, the program control motion of laying, descend.
The shaping at first kind of die assembly mode crank throw position realizes by sliding block and the small-sized hydraulic mechanism that self disposes on every group of mould.
The shaping at second kind of die assembly mode crank throw position is finished by being located at the relative floor displacement mechanism that respectively organizes in the mould.
In order to judge that accurately the crankshaft crank position is shaped opportunity, be provided with by computer and automatic feed mechanism, constant temperature automated procedure and mend the rotating speed of slag mechanism, the automatic monitoring display device that pressure sensor constitutes, be used for judgement and the demonstration of the dynamic coordinate Z of metal bath liquid level (t).Simultaneously, in order accurately to judge crucial " interface " (interface refers to melt the interface of slag bath and metal bath), the lower edge coordinate Zn (n=1,2 of each crank throw ... n), voltage or the electric current of establishing judgement, demonstration Zn again separately at the convenient place of each primary crystallization wall face returned " 0 " device.This device is by inserting the crystallizer forming cavity and connecting and composing with the conductive probe of crystallizer insulation, curtage table, computer and the hearth electrode that is located on the supervisory control desk.When Z (t)=Zn (n=1,2 ... n) time, " 0 " is returned in the curtage short circuit, and each crank throw builder of computer control is punctual, correct operation, and dual fail-safe ground realizes that the safety of each crank throw is shaped.
Below the following turntable of supporting die sinking machine, establish four column bearing supports, the frame top is the support ring of turntable under the supporting, be connected cooperation with cone bearing between support ring and the following turntable, drive the outside that motor that the die sinking machine rotates and electrodeless variable-speed transmission mechanism are installed in four column bearing supports; Respectively establishing two straight-line rollings on monolateral two columns of four column bearing supports pays, the hearth electrode of two alternations is paid on the column that is installed in separately by rolling respectively, on the hearth electrode lifting pedestal, establish the leading screw screw, its top was hinged on below the support ring after the hearth electrode elevating screw passed screw, driven wheel is installed in the lower end, driven wheel is connected with drive motors on being installed in the basis by stepless time adjustment mechanism, installation rate sensor, signal line and amplify command link and be connected with computer by interface on each motor shaft.Fixedly connected hydraulic-driven quadric chain on the hearth electrode lifting pedestal, the other end of quadric chain is established the hearth electrode supporting plate, establish jaw type water-cooled hearth electrode bearing in hearth electrode supporting plate upper end, its tong arm is free heart waterway, by recirculated cooling water it is forced cooling, coated insulating coating on jaw type water-cooled hearth electrode bearing, the isolation of two lobe hearth electrodes by insulating coating, be fixedly connected on the jaw type water-cooled hearth electrode bearing, constitute indirect water-cooling formula hearth electrode, hearth electrode is connected with the output of power transformer by soft net, red copper row.
The feature of recirculating cooling water system is: the water source is the adjustable water supply installation of frequency control constant voltage, establishes flowmeter, temperature sensor, pressure sensor on its water main.The water main divides two-way: wherein one the tunnel be responsible for supplying water to the pressure water storing tank, make it keep the standing pressure water yield, aim at the usefulness of protection mould when unusual the power failure occurring, therefore, establish pressure sensor, liquid level gauge on the pressure water storing tank, pressure water storing tank outlet is communicated with the supply channel of mold system by the manual ball valve that is installed on the master control platform; Another road is divided into a plurality of branch roads (crystallizer in way 〉=mold system, the number of sliding block or displacement layer and hearth electrode bearing waterway), establish flow on each branch road, pressure sensor, and pass through electric control valve, flexible pipe, joint is communicated with the import of each waterway, the delivery port of each waterway passes through flexible pipe, joint and corresponding transparent discharge casing inlet connection, in the inlet of transparent discharge casing, establish the temperature transducer of monitoring leaving water temperature, be marked with level scale at transparent discharge casing sidewall, be convenient to naked-eye observation draining operating mode, the outlet of transparent discharge casing is communicated with main sewer.Main sewer imports total storage cistern, total storage cistern set up defences dirt, heat radiation, filter.Characteristic area (high-temperature region) at each waterway master working face is established temperature sensor.On each primary crystallization device sealing blanking cover, offer the sealed transparent observation window, adorn safe valve.The execution loop of each flow, pressure, temperature, liquid level signal sensor and each electric control valve is communicated with computer by interface, forms the recirculating cooling water system of implementing " distribution according to need, weight feed " water system.
Production run method of the present invention is:
(1) preparatory stage: consutrode send the structure of meeting sb. at the airport, automatic feed mechanism interlock to set consutrode to the preceding state of start; The temperature control system that the constant temperature automated procedure is mended slag mechanism starts, and slag system is preheating to design temperature; Both arms droop manipulator is placed in three layers of mould of initialization on the die sinking machine of initial position; The well initial starting rod of hearth electrode clamping rises and contacts cooperation (cooperate with the hearth electrode upper surface heat-proof combustion-resistant insulating thin is housed, its outside diameter is greater than the bottom diameter of bed die forming cavity) with bed die forming cavity bottom outlet centering; Initial slag device starts in good time prepares fusing slag liquid.
(2) the continuous cropping formula production phase: recirculating cooling water system starts, each mould layer is supplied with cooling water respectively with the water system of " distribution according to need; weight feed " on the split cavity machine, initial thereupon slag device quantitatively injects the mould molding chamber with the slag liquid of getting ready, and in time start power-supply system, set up the electroslag process steadily; When the electroslag process is set up, each system and relevant servicing unit enter program control duty, at first mend of the requirement of slag mechanism according to the rate of change and its corresponding required electrical power rate of change of mold system forming cavity known volume by automatic feed mechanism and constant temperature automated procedure, feed speed, the amount of feeding by the computer control consutrode, process is mended slag speed, is mended the quantity of slag, make process mend best depth of slag bath H (t) scope that slag guarantees setting, make consutrode immerse the degree of depth h of slag bath Q(t) keep stable submerged arc work, make the distance h of comsumable melt end and metal bath liquid level R(t) (key value in decision slag thermal resistance source) realizes quantitatively control down, and reproducible optimum distance change curve is established the basis that the continuous cropping formula is produced thus.When Z (t)=Zn (n=1,2 ... when n) the crank throw shaping occurred opportunity, the hydraulic pressure crank throw builder smooth starting on each mould layer of computer control, was finished the shaping of each crank throw exactly at safety.When Z (t) rises up into several the 3rd layer of die cavity from bottom to top, both arms droop manipulator is clamped two die units of the 4th layer of mould from support, promote, rotation, contraposition, matched moulds, being placed on the top of the 3rd layer of mould the back throws off, go to the desired location of second layer die unit back then with last turntable, the clamping working head and the push rod of unblanking on the both arms droop manipulator are worked respectively, be responsible for clamping second layer mould by the clamping working head, and give quiet support force, the push rod of unblanking is responsible for backing down the locking device of two die units of ground floor mould, and the push rod of unblanking after backing down is return automatically.The machine of die sinking is simultaneously opened two die units of ground floor mould, delivers to the wait operating position on the annular base station.After finishing ground floor die sinking work; the die sinking machine goes to next Support Position automatically; lifting platform and hearth electrode steadily descend synchronously; in place on the die sinking machine each the mould layer in the work of droop manipulator static(al) support; back in place both arms droop manipulator is thrown off; lifting platform steadily rises to former height, the rate of climb of the feed speed of consutrode automatic feed mechanism stack lifting platform in the process that lifting platform rises.Turntable drive droop manipulator goes to the next one and removes the mould orientation in the process that lifting platform rises, and after the lifting platform playback, the droop manipulator is put into the operating position with waiting two die units of one deck down on time.By that analogy, mould and operational system are produced motion by the program control continuous cropping formula of carrying out.
Double bottom electrode alternation program is: after entering second life cycle of the product die sinking machine and opening the bottom mould, in the process that lifting platform steadily descends, need to suspend on specified altitude in the way that descends.At this moment two small sand wheel mechanisms that are located at down the turntable inboard stretch out; in with die sinking machine rotating process; skull on the hearth electrode clamping zone that will be replaced on the product is removed and the shaping of light mill; after cleaning work is finished; the small sand wheel mechanism is return original position; the die sinking machine is parked in the regulation Support Position, and the mould layer that lifting platform continues to descend in the work is placed on the die sinking machine.The upper and lower arm of getting the workpiece manipulator stretches out successively, and its underarm and hearth electrode descend synchronously and finish the holding workpiece action, and the hearth electrode alternation is finished, and cutter cuts workpiece, gets the workpiece manipulator and descends, and rotation is placed on workpiece on the conveyer bridge.
Advantage of the present invention is: present technique equipment adopts the optimum organization mode of mold system and the demoulding and each die unit follow procedure three-degree-of-freedom motion method successively from bottom to top, save die cost 30-50% than prior art equipment, turning of bent axle is several many more, the dimensional weight of product is big more, and the die cost of saving is many more; Present technique equipment can be saved energy consumption about 30% owing to implement the cooling water system of " distribution according to need, weight feed "; Present technique equipment adopts the feeding of consutrode and the synchronous follow procedure of process benefit slag to move automatically, than prior art with the manual feeding consutrode of a people, another people manually mends the mode of slag, can accurately control the distance h at depth of slag bath H (t) and consutrode termination to interface R(t), get rid of the random disturbances of human factor, make the electroslag process realize the quantitative state of control automatically the electroslag process; Present technique equipment employing mould operational system is operated each die unit and is carried out three-dimensional space motion automatically, swings the present situation that sledgehammer is broken mould than prior art equipment with 2-4 people, realizes carrying out production strictly in line with rules and regulations, and reduces labor intensity, and prolongs die life; Present technique equipment is realized the quantitative control to electricity, slag, water, mould four big parameters, makes the crystallization temperature field have repeatability, thereby can obviously improve the size of product and the uniformity of interior tissue; Present technique equipment is compared to produce 10,000 6V automobile crane blanks with prior art equipment, and raw material can be saved 90 tons, and electric power can be saved 270,000 degree, and the mould expense can be saved 30-50%, and the labour can save more than 90%, and production efficiency can double.Present technique equipment is compared with forging equipment, build identical large-scale production line (ability of an automobile crane blank of production in per three minutes) equipment investment and can save 2/3, electric power can be saved about 30%, place, factory building are saved more than 30%, the labour can save more than 20%, can improve in The comprehensive performance and service life about 30%, work situation can be realized culturally advanced.For in, the required bent axle of high-power Diesel engine and an axle class part product (as: tank, self-propelled gun, battlebus, diesel locomotive, heavy duty vehicle, mining machinery, naval vessels and steamer etc.) adopt present technique equipment to compare with existing FMT equipment, equipment investment can be saved more than 2/3, energy consumption is saved more than 15%, material and back road machining man-hour and equipment loss can be saved more than 25%, and mechanical performance of products and service life can improve about 30%.The present invention is applicable to continuous cropping, the near-net-shape blank of various bent axles and axle class part.
Below in conjunction with drawings and Examples, the present invention is further described:
Fig. 1 is the general structure schematic diagram of the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle and axle class part;
Fig. 2 is a consutrode automatic feed mechanism schematic diagram;
Fig. 3. be that consutrode send the structure schematic diagram of meeting sb. at the airport;
Fig. 4. be that the constant temperature automated procedure is mended the slag structural scheme of mechanism;
Fig. 5. be the composition schematic diagram of sliding block extruding type mold system;
Fig. 6 is the B-B view of Fig. 5
Fig. 7 is the composition schematic diagram of relative floor displacement formula mold system;
Fig. 8 is the C-C view of Fig. 7
Fig. 9 is a Double bottom electrode mechanism schematic diagram;
Figure 10 is the top view partial sectional view of Fig. 9
Figure 11 is a slide block type crank throw shaping work schematic diagram in the mould molding chamber;
Figure 12 gets workpiece manipulator schematic diagram;
Figure 13 is the partial view of Figure 12
Figure 14 is the recirculating cooling water system schematic diagram.
As seen from Figure 1, the present invention is made up of seven systems and servicing unit (comprising: water swashs in the dedusting and air filter, receive the housing apparatus of mucking haulage, initial molten slag device, non-consumable electrode and remedy defective goods device etc.) as the electroslag melting cast near-net-shape equipment of a kind of continuous cropping formula bent axle and axle class part, and wherein seven systems are:
The agent structure system comprises: ring platform shape support (10), and board-like annular base station (14), lifting platform (11), last turntable mechanism (12), following turntable mechanism (15), four column bearing supports (4) are formed.
Feeding system comprises: consutrode send the structure of meeting sb. at the airport (1), and consutrode automatic feed mechanism (2), constant temperature automated procedure are mended slag mechanism (3) and formed.
Power-supply system comprises; Top electrode (7), hearth electrode A and executing agency (6), end motor A ' and executing agency (5), power transformer and stube cable, copper bar etc. (annotating: not shown).
Mould and operational system comprise: in running order three layers of mould (8) in the building block system mold system; be in each die unit (9) of wait state; both arms droop manipulator (13); die sinking machine (15) (annotate: with play turntable mechanism with a sequence number), the drive unit of (13) and (15) and each motion signal sensor, circuit, interface (notes: not shown) composition.
Getting the fortune workpiece system comprises: cutting gun (17), (18), get workpiece manipulator (16), (17), the driving mechanism of (18) (annotating: not shown), each motion signal sensor, cable, the interface (annotating: not shown) that are contained on (16), (17), (18) are formed.
Recirculating cooling water system comprises: the adjustable water supply installation of frequency control constant voltage, flexible pipe net, joint, transparent discharge casing (unnumbered among the figure) electrically-controlled valve, pressure, flow, temperature sensor and Displaying Meter are communicated with the back and form (annotating: not shown), standby pressure water storing tank (26) with each die unit in the mold system.
Control system comprises: electromagnetic shielding chamber (19), and supervisory control desk (20), each road sensor signal (is annotated the input interface of computer and the instruction output interface of each executing agency of computer control; Not shown).
Servicing unit comprises; Video camera (21), water swashs in the dedusting and air filter (22), receives the housing apparatus (23) of mucking haulage, hydraulic power source device (24), pneumatic supply device (25), initial molten slag device, non-consumable electrode are remedied defective goods (refer to have a power failure and cause because of accident defective goods) device (annotating: not shown).
As seen from Figure 2, the Z of consutrode automatic feed mechanism to driving and reversing mechanism by frame (27), press frame (28), be contained in active wheels (29) on (27), be contained in driven wheels (46) on (28), with fastening spring assembly (30), consutrode (41) is compacted to makes (41) roll extrusion between (27) and (28) free to advance or retreat, do not produce the appropriate level of slip.Initiatively wheels connect with driving-chain (31), and be connected to the motors (35) of advancing and retreat with Z by transmission shifting mechanism (32), (33), on (35), establish the sensor (34) of monitoring advance and retreat speed, the rate signal of being obtained by (34) carries out the A/D analog-to-digital conversion after amplifier amplifies in process of production, again by after the Computer Processing, output D/A digital-to-analogue conversion command signal, control executing agency carries out the program motion of Z to advance and retreat.X to adjusting device by X to base (39), connect (27) and pay (36) with the straight-line rolling of (39), the X that is contained on (39) forms to the signal transducer (annotating: not shown) of adjusting motor, variable transmission mechanism (45) and monitoring motor speed.Y to adjusting device by Y to base (44), connect (39) and pay (37) with the straight-line rolling of (44), the Y that is contained on (44) forms to the signal transducer (annotating: not shown) of adjusting motor, variable transmission mechanism (40) and monitoring motor speed.
For the dynamic burn-off rate and the fusing amount of monitoring consutrode, accurately show Z (t) value, between (44) and lifting platform (11), establish pressure sensor group (38) and (43), pressure sensor signal amplifies through amplifier, carry out the A/D analog-to-digital conversion, machine is to burn-off rate as calculated, the fusing amount, mold system forming cavity known volume amount, process is mended the quantity of slag, after the computing of crust consumption, draw Z (t) value, be presented on the monitor with cartoon technique, as Z (t)=Zn (n=1,2, n) time, send crank throw moulding instruction, control the safety shaping that each executing agency finishes the crankshaft crank position.
Below frame (27), be connected with top electrode (7) suspension by insulation gimbals (42).On frame (27) with (27) guide cylinder (47) of consutrode of being spirally connected that is connected.
As seen from Figure 3, consutrode send the structure of meeting sb. at the airport to be made up of two parts: wherein (48)~(56) are both arms continued access part, and part is transported for promoting in (57)~(61).Their program control ruuning situation is: feeding elevator (59) is under the control of travel switch (annotating: not shown), along guide rail column (57) consutrode (41) on rotation bin (61) in place is risen to specified altitude, (61) under the driving of step drive device (60), consutrode (41) is rotated to treat clip position in regular turn.(57) paying (58) by Z to the guide rail that is slidingly connected with lifting platform shown in Figure 1 is connected.At this moment, hydraulically powered lifting column (56) drives (48)~(55) and raises under the control of travel switch (annotating: not shown).Simultaneously, corner executing agency (55) drive consutrode that rotating shaft (53) is in both arms continued access partial rotation in (61) to treat clip position directly over, at this moment lifting column (56) descends, make top that the three-jaw chuck (49) that is installed on the upper arm (51) is inserted in (41) to predetermined distance, screw motor (50) driving (49) finishes separating with (49) after (41) clamping action thereupon, be contained in the relevant position of hydraulic tongs (52) clamping (41) on the underarm (54), on, following clamping back (56) drives (48)~(55) spacing and rises, the lower end of (41) the is lifted away from supported hole seat of blanking rack of (61), rotation angle mechanism (55) drive (48)~(54) with the consutrode of clamping rotate to feeding in the consutrode coaxial position, (56) driving (48)~(55) steadily descends, make the consutrode of clamping insert guide cylinder on the automatic feed mechanism, when consutrode top in the feeding contacts, (56) changing decrease speed is the feed speed of consutrode, hydraulic tongs (52) is removed clamping force, make consutrode and jaw keep the support state of sliding-contact, at this moment after the screw that the motor (48) that spins drives consutrode upper end in spiral shell head that (49) make the consutrode lower end in the clamping and the feeding was torqued-up to regulation moment, screwing mechanism (50) recovery contacted with the transmission of (49).In time (48) are unclamped, so far finish sending of a consutrode and connect program control motion.By that analogy, the control that sending of consutrode in the continuous cropping formula production process is connect be operated in computer realizes the mechanization operation down.
As seen from Figure 4, the constant temperature automated procedure is mended slag mechanism by temperature control storage slag case (63), (66), drive motors (64), (68), spiral slag adding machine (65), (67), they are bearing on the turntable (12) by pressure sensor (62), and two temperature control storage slag casees and both arms droop manipulator shown in Figure 1 are 90 ° of angle layouts.Temperature control storage slag case is mended slag by the electric calorifie installation implementation process thermostatic control; Dynamically mend the quantity of slag in the fusion-casting process according to the variable quantity of mold system forming cavity volume, the consumption that slag crusts and the demand that keeps best depth of slag bath, by the programme-control of computer by (62), (64), (68), (65), (67), implementation procedure benefit slag.In order to make slag bath stable components, physical and chemical performance good, the volatile loss composition of the available temperature control storage special supply of slag case as CaF, needs formulate special-purpose replenishing program according to skull Z to the sample examination result for this reason, implements by computer control.
By Fig. 5 and Fig. 6 as seen, the mold system that the sliding block extruding type is shaped crank throw, two die units that it is split by bottom are formed the first mould layer (69), form backform layer (73) by two die units that top layer is split, three layers of two die unit that the crank throw forming cavity is split, establish crowded mechanism and the stroke of turning of hydraulic pressure sliding block on the external mold extension arm of one of them die unit, Zn surveys, temperature, the adapter assembly of alarm signal sensor (annotating: not shown) is connected with computer interface, these three crank throw finishing die layers are respectively (70), (71), (72), their composition form such as Fig. 6 B-B view (72-1), (72-2).On (73), establish one deck and split water-cooled and protect slag cover (74), use for producing when finishing.The quantity of the water mold in each die unit can be according to the division of crystallization temperature field warm area, correspondence is provided with crystallizer (annotating: not shown), they are carried out being installed in after the building block system combination split on the external mold, control the recirculated cooling water amount of each crystallizer respectively, so that obtain reproducible best crystalline forming temperature field.The advantage of this method be simple in structure, cost is low, shortcoming is that the crank throw throat area is the shape of a hoof more, the large angiopteris rhizome surplus increases the weight of later process burden.
By Fig. 7 and Fig. 8 as seen, the mold system that relative floor displacement formula crank throw is shaped, two die units that it is split by bottom are formed bottom mould (75), split two die units by top layer and form top layer mould (79), the band relative displacement layer of three pairs of same structures and the die unit of hydraulic actuating mechanism form (76) respectively, (77), (78) layer mould.For example Fig. 8 C-C view of (78) layer mould is established two parallel synchronous operation hydraulic mechanisms (annotating: unnumbered among the figure) on (78-1), is responsible for promoting that displacement layer finishes that crank throw is shaped, returns original position after the die sinking.(78-2) establish a hydraulic mechanism (annotating: unnumbered among the figure); responsible promotion is located at the half block displacement layer between (78-2) external mold slide rail and is located at half block displacement layer matched moulds between (78-1) external mold slide rail, and the hydraulic mechanism pressure behind the matched moulds on (78-2) makes zero and enters driven state.On (79), establish and split water-cooled and protect the slag cover, use during for completed product run.The adapter assembly of stroke, Zn detection, temperature, alarm signal sensor is installed in the appropriate location of each layer external mold as required, is connected with computer interface.This method advantage is to ensure that the crank throw neck is cylindrical, improves dimensional accuracy, reduces allowance.
By Fig. 9 and Figure 10 as seen, Double bottom electrode A and A ' do the program elevating movement respectively on electric up-down transmission mechanism (86).(87) be the jaw type hearth electrode, (88) for the clamping of (87), unclamp hydraulic mechanism, (89) conduct electricity soft net with (95) in the bent X that stretches, leads to power supply, the Y plane for being connected with (87) and rotating with (87), (90) be the hydraulic pressure quadric chain, (82) are the jaw type water-cooled hearth electrode bearing that is connected with (83).(87) and between (82) closely cooperate by insulating coating.(82) establish cooling water cavity on the tong arm and (87) are carried out indirect water-cooling by cooling water.The influence of cutter flame to (87) isolated in protection simultaneously; (83) be the hearth electrode supporting plate; (85) for leading to the soft net of conduction of power supply to stretching along Z with (83); (81) for connecting the soft net main line of conduction of hearth electrode and power supply; (92) be rectangle frame insulating frame, its one side is connected with (93), and (86) pass its rectangle endoporus; make A and A ' do the program elevating movement along (86), (93) be with (86) in the elevating bracket of leading screw usefulness threaded engagement.The guide rail of paying in (86) by linear rolling track cooperates, and under the motor in (86), the driving of transmission mechanism, realizes the lifting program motion of A and A '.(90) link to each other with (83), (93).Motion under its hydraulic actuator in (90) drives.The speed of monitoring A and the motion of A ' ALP, stroke, clamping, pine rise, each signal transducer is connected with computer interface.
As seen from Figure 11, the slide block type crank throw shaping course of work in the die forming chamber, (96) are the mould molding chamber, and (97) are the slag crust, and (98) are the fusing slag bath.(7) be top electrode, (41) are the comsumable melt end, and its degree of depth that immerses slag bath is h Q(t), (99) for passing the metal drop of slag bath after melting, (100) are metal bath, and the distance of its surface to the termination of (41) is h R(t), (101) are crystalline forming part, and (102) are h for thickness OSliding block, (A or A ') is hearth electrode, (103) be initial starting rod, (104) be Zn (n=1,2 ... n) probe, (105) be (104) and (A) between the current monitoring instrument, (106) be the high temperature insulation sleeve pipe, (107) be (104) and (A) between the voltage monitoring instrument, (108) are power supply.As seen from the figure, when the moment of liquid level Yu (104) contact short circuit of (100), voltage and current returns " 0 " to show, at this moment Z (t)=Zn (n=1,2 ... n), just (102) clamp-on the correct opportunity that the crank throw position is shaped.
As Figure 12 and 13 as seen, get the workpiece manipulator in continuous cropping formula production process, for preventing workpiece deformation and alleviating the pressure of workpiece to hearth electrode, rotation, lifting, telescopic arm (109) drives to be driven to go to horizontal by 90 ° hand frame (110) by hydraulic pressure rotation angle mechanism (117) and enters holding fix, last hydraulic tongs (116) is in and opens wait state, following hydraulic tongs (115) makes down under the driving of electric lifting mechanism (114), and the pincers seat rises to above (116) by the open hydraulic tongs (116) of going up along leading screw (112) and slide rail (111), when first retaining part of workpiece of setting arrives at waiting (115), following hydraulic tongs clamping work pieces, after this (115) just under the manipulation of control system with the synchronous descending motion of lifting platform, when the retaining part of second setting on the workpiece arrives at hydraulic tongs (116), when promptly finishing the production cycle of a product, (116) clamp second retaining part of workpiece, after cutting gun cuts finished piece(s), (109) descend, withdrawal, (117) make (110) forward horizontal level in the time of rotation, (115), (116) unclamp workpiece is placed on the support of transveyer reposefully.Repeat as above program control motion then.
As seen from Figure 14, water-cooled is protected slag cover O, O ', mold system each crystallizer I, I ', and II, II ',
III, III ', IV, IV ', V, V ', VI, VI ', sliding block N1, N2, N3, N4 and hearth electrode support tong arm waterway H, H ' supply water through corresponding electric control valve (122) and flowmeter (annotating: not shown) by the adjustable water supply installation of frequency control constant voltage (118).Their delivery port flows into total storage cistern that main sewer returns (118) by the hose coupling corresponding transparent discharge casing (124) of flowing through respectively.Monitoring leaving water temperature sensor (123) is installed in the inlet of each transparent discharge casing (124), establish monitoring waterway master's working face temperature sensor (121) in the high-temperature characteristic district of each crystallizer, sliding block and hearth electrode support tong arm waterway, establish monitoring inflow temperature sensor (119) and water inlet total flow meter (annotating: not shown) at total feed pipe.The water inlet of standby pressure water storing tank (120) is connected with (118) by magnetic valve (annotating: unnumbered among the figure), and its outlet is led to each waterway by valve sets in parallel (annotating: unnumbered among the figure), and manual ball valve is located on the supervisory control desk in the valve sets in parallel.When unusual the power failure occurring, mould is protected in the manual unlocking water flowing.The cable run of each temperature sensor, flow, pressure and electric control valve is connected with the input of computer, output interface.Under the control of computer,, realize the recirculated cooling water system of " distribution according to need, weight feed " by each crystallizer, the requirement of waterway characteristic point temperature variation curve.

Claims (8)

1, the electroslag smelting casting near-net-shape equipment of a kind of continuous cropping formula bent axle and axle class part comprises agent structure system, feeding system, power-supply system, mould and operational system, gets fortune workpiece system, recirculating cooling water system and control system, it is characterized in that:
(1) agent structure is made up of ring bench-type support, lifting platform, last turntable, following turntable and four column bearing supports, support is ring platform shape hollow slab type structure, corresponding each die unit of periphery is established transparent discharge casing, establish 2-4 hydraulic lifting column on the support, lifting platform is established on hydraulic lifting column top, and turntable is established in the lifting platform below, and the upper surface of support is board-like annular base station, centering is provided with down turntable below the annular base station, four column bearing supports is set below the following turntable;
(2) feeding system, send the structure of meeting sb. at the airport, consutrode automatic feed mechanism and mend slag mechanism with the constant temperature automated procedure of its synchronous operation and form by consutrode, top and side that consutrode send the structure of meeting sb. at the airport to be arranged on the consutrode automatic feed mechanism, the consutrode automatic feed mechanism is arranged on middle position on the lifting platform, and two constant temperature automated procedures are mended the suspension of slag mechanism and are arranged on the turntable below;
(3) power-supply system is made up of Double bottom electrode, the power transformer of top electrode, alternation automatically, and the top electrode insulation is hung and is arranged on consutrode automatic feed mechanism below, respectively establishes a hearth electrode on wherein two root posts of four column bearing supports;
(4) mould and operational system by the executing agency that building block system mold system and each die unit carry out the motion of three dimensions program, comprise support, lifting platform, last turntable, support, following turntable and both arms droop manipulator die sinking machine; Last turntable is divided into and its fixing both arms droop manipulator that is connected that hangs, park each die unit of wait work on the anchor ring of base station in regular turn, the die sinking machine is connected on the following turntable, be symmetrical arranged two the hydraulic pressure die sinkings in every limit head on the die sinking machine, a die sinking upper support, in running order each layer mould in location, inboard and die sinking head at the die sinking machine are 90 ° of layouts, establish the emery wheel mechanism of two small-sized automatic advance and retreat;
(5) get the fortune workpiece system, by cutting gun, get the workpiece manipulator, the workpiece conveyer is formed; The four column bearing supports outside below the die sinking machine is established and is got the workpiece manipulator; below each hearth electrode, establish cutter; the pincerlike support of hearth electrode, the insulation blocking of band waterway are arranged between cutter and the hearth electrode, establish conical hopper and conveyer belt composition in the bottom of four column supports and receive the housing apparatus of mucking haulage.
2, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, the consutrode automatic feed mechanism compresses transmission mechanism for the spring roller, initiatively frame and the pressure frame of adorning driven wheels of wheels and holddown spring, screw rod, planning standard spare are formed idler wheel mechanism by dress, on frame, establish vertical Z to motor and stepless time adjustment drive unit, on the output shaft of motor, establish speed probe at Z; Below frame, establish successively horizontal X to, Y to adjusting base, establish X, Y fine setting motor and stepless time adjustment drive unit on the base respectively adjusting, and on each fine setting electric machine main shaft, establish speed probe; Between adjustment base and lifting platform, be provided with the pressure sensor supporting;
3, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, the consutrode that is arranged on consutrode automatic feed mechanism top and side send the structure of meeting sb. at the airport by the feeding elevator, lifting column, rotating mechanism and up and down both arms continued access mechanism form, establish electronic three-jaw chuck on the upper arm and decide that moment is tightened and tripping-gear, establish hydraulic tongs on the underarm.
4, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, symmetrically arranged two constant temperature automated procedures are mended slag mechanism and are made up of temperature control storage slag case, spiral slag adding machine, temperature control is store between slag case and the last turntable and is supported by pressure sensor, and spiral slag adding machine water conservancy diversion ozzle is aimed at mold system forming cavity top mouth near consutrode.
5, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, the sliding block extruding type mold system of building block system mold system is by one group of bottom mould, one group of top layer mould, three layers of phase similar shape chamber, have that the mould of sliding block hydraulic pressure crank throw shaping mechanism is vertical stackedly to be constituted.
6, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, the relative floor displacement formula mold system of building block system mold system is had by one group of bottom mould, one group of top layer mould, three groups that the mould of relative floor displacement mechanism is vertical stackedly to be constituted.
7, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, the hearth electrode of two automatic alternations, pay on the column that is installed in separately by rolling respectively, on the hearth electrode lifting pedestal, establish the leading screw screw, the hearth electrode elevating screw passes below the support ring that its top behind the screw is hinged on down turntable, driven wheel is installed in the lower end, driven wheel is connected installation rate sensor on each motor shaft by stepless time adjustment mechanism with drive motors on being installed in the basis, signal line and amplification command link are connected with computer by interface.Fixedly connected hydraulic-driven quadric chain on the hearth electrode lifting pedestal, the other end of quadric chain is established the hearth electrode supporting plate, establish jaw type water-cooled hearth electrode bearing in hearth electrode supporting plate upper end, its tong arm is free heart waterway, by recirculated cooling water it is forced cooling, coated insulating coating on jaw type water-cooled hearth electrode bearing, two lobe hearth electrodes are fixedly connected on the jaw type water-cooled hearth electrode bearing by the isolation of insulating coating, constitute indirect water-cooling formula hearth electrode, hearth electrode is connected with the output of power transformer by soft net, red copper row.
8, the electroslag smelting casting near-net-shape equipment of continuous cropping formula bent axle as claimed in claim 1 and axle class part, it is characterized in that, recirculating cooling water system comprises the adjustable water supply installation of frequency control constant voltage, the flowmeter of establishing on the water main, temperature sensor, pressure sensor, the water main divides two-way: wherein one the tunnel supply water for the pressure water storing tank, establish pressure sensor, liquid level gauge on the pressure water storing tank, pressure water storing tank outlet is communicated with the supply channel of mold system by the manual ball valve that is installed on the master control platform; Another road is divided into a plurality of branch roads, establish flow on each branch road, pressure sensor, and pass through electric control valve, flexible pipe, joint is communicated with the import of each waterway, the delivery port of each waterway passes through flexible pipe, joint and corresponding transparent discharge casing inlet connection, in the inlet of transparent discharge casing, establish the temperature transducer of monitoring leaving water temperature, be marked with level scale at transparent discharge casing sidewall, the outlet of transparent discharge casing is communicated with main sewer, main sewer imports total storage cistern, characteristic area at each waterway master working face is established temperature sensor, on each primary crystallization device sealing blanking cover, offer the sealed transparent observation window, adorn safe valve, each flow, pressure, temperature, the execution loop of liquid level signal sensor and each electric control valve is communicated with computer by interface.
CN98101898A 1998-05-26 1998-05-26 Electroslag casting shaper for continuous making of crankshafts and shaft parts Expired - Fee Related CN1051036C (en)

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CN98101898A CN1051036C (en) 1998-05-26 1998-05-26 Electroslag casting shaper for continuous making of crankshafts and shaft parts

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Application Number Priority Date Filing Date Title
CN98101898A CN1051036C (en) 1998-05-26 1998-05-26 Electroslag casting shaper for continuous making of crankshafts and shaft parts

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CN1051036C CN1051036C (en) 2000-04-05

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1309509C (en) * 2002-08-21 2007-04-11 蒋雪耕 Step electroslag melting technology and apparatus for crankshaft blank
CN102703720A (en) * 2012-01-20 2012-10-03 苏州振吴电炉有限公司 Mechanical arm for stably controlling electrode of electric slag furnace
CN102703722A (en) * 2012-01-20 2012-10-03 苏州振吴电炉有限公司 Tower-type furnace end lifting mechanism of electro slag furnace
CN102703721A (en) * 2012-01-20 2012-10-03 苏州振吴电炉有限公司 Conductive automatic clamping device for electrode of electric slag furnace
CN103128260A (en) * 2011-12-02 2013-06-05 天津市三焱电渣钢有限公司 Electroslag casting marine diesel engine crankshaft smelting device
CN107790685A (en) * 2016-08-31 2018-03-13 沈阳铸造研究所 Electroslag smelting casting method without public die cavity casting is prepared using the molten group equipment of intelligence

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CN1069073C (en) * 1999-04-16 2001-08-01 南昌大学 Electroslag casting apparatus for castings with complex shapes
CN102703724B (en) * 2012-01-20 2013-08-07 苏州振吴电炉有限公司 High-current coaxial-sliding electrically conductive current collecting device of electro slag furnace

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CN1006531B (en) * 1985-04-01 1990-01-24 北京科技大学 One step electroslag melt-casting process for integral crankshaft and equipment used
CN1014213B (en) * 1986-12-27 1991-10-09 江西黎川特钢厂 Improved electroslag melting device for crankshaft blank

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1309509C (en) * 2002-08-21 2007-04-11 蒋雪耕 Step electroslag melting technology and apparatus for crankshaft blank
CN103128260A (en) * 2011-12-02 2013-06-05 天津市三焱电渣钢有限公司 Electroslag casting marine diesel engine crankshaft smelting device
CN102703720A (en) * 2012-01-20 2012-10-03 苏州振吴电炉有限公司 Mechanical arm for stably controlling electrode of electric slag furnace
CN102703722A (en) * 2012-01-20 2012-10-03 苏州振吴电炉有限公司 Tower-type furnace end lifting mechanism of electro slag furnace
CN102703721A (en) * 2012-01-20 2012-10-03 苏州振吴电炉有限公司 Conductive automatic clamping device for electrode of electric slag furnace
CN102703720B (en) * 2012-01-20 2013-09-18 苏州振吴电炉有限公司 Mechanical arm for stably controlling electrode of electric slag furnace
CN107790685A (en) * 2016-08-31 2018-03-13 沈阳铸造研究所 Electroslag smelting casting method without public die cavity casting is prepared using the molten group equipment of intelligence
CN107790685B (en) * 2016-08-31 2019-09-24 沈阳铸造研究所 Electroslag casting method without public chamber casting is prepared using the molten group equipment of intelligence

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