Processing system for processing a cast raw casting and method for producing a cast component

Abstract

A processing system and method for processing a cast raw casting has a spray system for cooling the raw casting. The spray system has at least one nozzle device for at least temporally, locally, or quantitatively variable application of a free-flowing medium to at least one section of the raw casting. The processing system also has a temperature measuring device for measuring the temperature on at least one section of the raw casting and a monitoring device for controlling and adjusting the nozzle device as a function of the measured temperature.

Claims

1. A processing apparatus for processing a cast raw casting, the processing apparatus comprising: a spraying apparatus for cooling the raw casting, said spraying apparatus having at least one nozzle device for temporally, spatially, or quantitatively variable application of a flowable medium to at least one section of the raw casting; a temperature measurement device for measurement of temperature at at least one section of the raw casting; and a control device operatively configured to control and regulate the at least one nozzle device as a function of measured temperature; wherein the processing apparatus is configured to coarsely deburr and finely deburr the raw casting during a single processing step.

2. The processing apparatus according to claim 1, further comprising: a geometry measurement device for measurement of at least one geometry of the raw casting.

3. The processing apparatus according to claim 2, further comprising: a comparison device that: (i) compares a value of the measured temperature with a reference temperature value, and/or (ii) compares a value of the measured geometry with a reference geometry value.

4. The processing apparatus according to claim 1, wherein the at least one nozzle device has at least one two-substance nozzle for application of two mutually different flowable substances to the raw casting, and by way of the two-substance nozzle, the two mutually different flowable substances are combinable in a quantitatively variable fashion to form the flowable medium.

5. The processing apparatus according to claim 1, wherein the spraying apparatus has a plurality of nozzle devices arranged statically or movably relative to the raw casting to be cooled, the plurality of nozzle devices being arranged spaced apart from one another within the spraying apparatus.

6. A casting cell for producing a cast component, the casting cell comprising: a casting machine having at least, one cavity for generating a raw casting; and a processing apparatus for processing the raw casting, the processing apparatus comprising: a spraying apparatus for cooling the raw casting, said spraying apparatus having at least one nozzle device for temporally, spatially, or quantitatively variable application of a flowable medium to at least one section of the raw casting; a temperature measurement device for measurement of temperature at at least one section of the raw casting; and a control device operatively configured to control and regulate the at least one nozzle device as a function of measured temperature; wherein the casting cell is configured to coarsely deburr and finely deburr the raw casting during a single processing step.

7. The casting cell according to claim 6, wherein the processing apparatus further comprises: a geometry measurement device for measurement of at least one geometry of the raw casting.

8. The casting cell according to claim 6, wherein the processing apparatus further comprises: a comparison device that: (i) compares a value of the measured temperature with a reference temperature value, and/or (ii) compares a value of the measured geometry with a reference geometry value.

9. The casting cell according to claim 6, wherein the at least one nozzle device has at least one two-substance nozzle for application of two mutually different flowable substances to the raw casting, and by way of the two-substance nozzle, the two mutually different flowable substances are combinable in a quantitatively variable fashion to form the flowable medium.

10. The casting cell according to claim 6, wherein the spraying apparatus has a plurality of nozzle devices arranged statically or movably relative to the raw casting to be cooled, the plurality of nozzle devices being arranged spaced apart from one another within the spraying apparatus.

11. A method for producing a cast component, the method comprising the acts of: casting a raw casting, via a casting machine, within at least, one cavity of the casting machine; measuring a temperature of at least one section of the cast raw casting via a temperature measurement device; and processing the cast raw casting by way of a flowable medium applied to the cast raw casting by a processing apparatus; wherein the raw casting is subjected to coarse deburring and fine deburring during a single processing step.

12. The method according to claim 11, wherein the raw casting is at least cooled or straightened via the flowable medium.

13. The method according to claim 12, wherein: the flowable medium is applied in a spray mist form to the raw casting, and application of the flowable medium is temporally, spatially, and/or quantitatively controlled via a control device.

14. The method according to claim 11, wherein at least one geometry of the raw casting is measured via a geometry measurement device.

15. The method according to claim 14, wherein: a value of the temperature measured by the temperature measurement device is compared, via a comparison device, with a reference temperature value, and/or a value of the at least one geometry measured by the geometry measurement device is compared with a reference geometry value.

16. The method according to claim 11, wherein the cast component is produced within one casting cell having: a casting machine having at least one cavity for generating a raw casting; and a processing apparatus for processing the raw casting, the processing apparatus comprising: a spraying apparatus for cooling the raw casting, said spraying apparatus having at least one nozzle device for temporally, spatially, or quantitatively variable application of a flowable medium to at least one section of the raw casting; a temperature measurement device for measurement of temperature at at least one section of the raw casting; and a control device operatively configured to control and regulate the at least one nozzle device as a function of measured temperature.

17. The method according to claim 11, wherein the act of processing the cast raw casting makes use of the processing apparatus comprising: a spraying apparatus for cooling the raw casting, said spraying apparatus having at least one nozzle device for temporally, spatially, or quantitatively variable application of a flowable medium to at least one section of the raw casting; a temperature measurement device for measurement of temperature at at least; one section of the raw casting; and a control device operatively configured to control and regulate the at least one nozzle device as a function of measured temperature.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a functional sketch of an embodiment of a processing apparatus according to the invention.

(2) FIG. 2 shows a flow diagram relating to an embodiment of the method for the processing of the raw casting.

(3) FIG. 3 shows a flow diagram relating to a further embodiment of the method for the processing of the raw casting.

(4) Elements of identical function and mode of operation are denoted in each case by the same reference designations in FIGS. 1 to 3.

DETAILED DESCRIPTION OF THE DRAWINGS

(5) FIG. 1 schematically shows a functional sketch of an embodiment of a processing apparatus 1 for the processing of a raw casting 20. The processing apparatus 1 has a spraying apparatus 2 having a nozzle device 3 and, in particular, a plurality of nozzle devices 3.1 to 3.7. The nozzle devices 3 or 3.1 to 3.7 are arranged along a transport path T within the processing apparatus 1 in order to apply a flowable medium M to at least sections or regions of the raw casting 20. The individual nozzle devices 3, 3.1 to 3.7 are advantageously arranged so as to be movable in a movement direction B, and in particular in an X, Y and/or Z direction, or in the direction of X, Y, Z axes, relative to the raw casting 20 to be cooled. Furthermore, it is possible for the nozzle devices 3, 3.1 to 3.7 to be movable rotatably about the X, Y and/or Z axes, and consequently in Dx, Dy and/or Dz rotation directions. It is, however, also contemplated for the individual nozzle devices 3, 3.1 to 3.7 to be arranged in static fashion within the processing apparatus, such that only the raw casting 20 moves along the transport path T.

(6) The raw casting 20 advantageously has a longitudinal axis L about which the raw casting 20 can rotate in the rotation direction D, such that it can be made possible for the flowable medium M to be applied to any section of the raw casting 20. It is furthermore contemplated for the nozzle devices 3, 3.1 to 3.7 to be arranged so as to be rotationally movable about the raw casting 20, or to be able to be moved such that, consequently, the nozzle device 3 or the nozzle devices 3.1 to 3.7 can rotate about the longitudinal axis L of the raw casting 20. The nozzle devices 3, 3.1 to 3.7 advantageously have at least three degrees of freedom in translational directions, and consequently in the X, Y and Z directions, and three degrees of freedom in rotation directions, and advantageously consequently in the Dx, Dy and Dz rotation directions.

(7) The processing apparatus 1 furthermore has a temperature measurement device 4 and a geometry measurement device 5, which are arranged along the transport path T in order to be able to measure or determine a temperature and, in particular, a surface temperature and a geometry, such as a length dimension or a width dimension or else an angle dimension, of the raw casting 20. The temperature measurement device 4 and/or the geometry measurement device 5 are advantageously arranged so as to be movable relative to the raw casting 20 in order to be able to cover any section of the raw casting 20 in order to consequently be able to determine the temperature and/or the dimensions of the raw casting 20 in any section. With regard to the possible degrees of freedom of movement of the temperature measurement device 4 and/or of the geometry measurement device 5, reference is made to the abovementioned degrees of freedom of the movement of the nozzle devices 3, 3.1 to 3.7, wherein, in the present case, it is assumed that the temperature measurement device 4 and/or the geometry measurement device 5 can also perform corresponding movements. This means that, as also already mentioned with regard to the nozzle devices 3, 3.1 to 3.7, it is contemplated for the temperature measurement device 4 and/or the geometry measurement device 5 to also be able to be arranged so as to be static, and consequently immovable relative to the raw casting 20, wherein it is however necessary in this case for at least the raw casting 20 to be moved in the translational direction T and/or in the rotation direction D, that is to say in the rotation direction D about its longitudinal axis L. Furthermore, it is contemplated for the geometry measurement device 5 and/or the temperature measurement device 4 to be composed of a plurality of measurement devices which are arranged spaced apart from one another in the processing apparatus 1.

(8) The individual nozzle devices 3, 3.1 to 3.7 and the temperature measurement device 4 and the geometry measurement device 5 are advantageously connected to a comparison device 10 via data communication lines 6. Here, it is also contemplated for the data transmission between the nozzle device 3, 3.1 to 3.7, the temperature measurement device 4 and/or the geometry measurement device 5 and the comparison device 10 to take place in wireless fashion, for example via Bluetooth or WLAN etc. The comparison device 10 advantageously serves for comparing the actual values relating to the temperatures, in particular the surface temperature, and/or to the individual dimensions or geometry values of the raw casting 20, as received from the temperature measurement device 4 and/or from the geometry measurement device 5, with in particular reference values that are advantageously stored in a memory device 10.1 of the comparison device 10. The comparison device 10 advantageously also has an evaluation device 10.2 which serves for determining which section of the raw casting 20 must still have flowable medium M applied thereto, and/or what mixing ratio the flowable medium M must have, and/or in what timeframe the respective section of the raw casting 20 must be wetted with the flowable medium M, in order in particular to realize continuous and uniform cooling of the raw casting 20 and advantageously prevent distortion of the component during the cooling process.

(9) Furthermore, in FIG. 1, the reference designation 7 denotes a control device which advantageously serves to control the individual nozzle devices 3, 3.1-3.7 of the spraying apparatus 2 in accordance with demand. It is thus contemplated that, after the determination of the temperature or of at least one temperature value of the raw casting 20, and/or after the determination of a geometry or at least one geometry value of the raw casting 20, the control device 7 is triggered so as, for example, to activate or deactivate at least some of the nozzle devices 3, 3.1-3.7, to control and/or regulate the spraying duration thereof, and/or to control and/or regulate the mixture ratio of the flowable medium, etc.

(10) FIG. 2 shows a flow diagram of a method for the processing of a raw casting. In a step S1, the raw casting, proceeding from the casting machine, is provided to the processing apparatus. In a subsequent step S2, the raw casting, and in particular at least one section of the raw casting, is impinged on with a flow of the flowable medium, which is in particular a water-air mixture, and is in particular wetted by way of the nozzle device. In a subsequent step S3, it is advantageously the case that, by way of the temperature measurement device, the temperature and, in particular, a surface temperature of at least one section of the raw casting is measured or detected and supplied to a comparison device which, in a step S4, compares the determined temperature measurement value, which may also be referred to as a temperature actual value, with a reference temperature value, and in particular with a threshold value, which is advantageously stored in a memory device of the comparison device, and which may also be referred to as temperature setpoint value. If the measured temperature actual value has a greater value than the reference temperature value, the method is continued with the step S2, and the corresponding section continues to be wetted with the flowable medium until the measured temperature actual value reaches the reference temperature value or threshold value, which is advantageously 50 C. or lower. Consequently, if the measured temperature actual value reaches the threshold value, the comparison device knows that at least the measured section of the raw casting has cooled to an adequate extent, such that the raw casting can be subjected to fine deburring. For this purpose, it is possible, in a further step S5, for the raw casting, and in particular the cooled raw casting, to be removed from the spraying apparatus and supplied to a deburring area. Consequently, in a final step S6, the deburring is performed, which is in particular a combination of a coarse deburring process and a fine deburring process. After the deburring of the raw casting, a cast component has been provided, which can consequently be arranged in a component assembly in order to produce a final product. It is furthermore contemplated for the step S5, and in particular the removal of the cooled raw casting from the spraying apparatus, to be omitted, in particular if the deburring itself, and in particular the fine deburring and/or coarse deburring, takes place, as illustrated in step S6, within the spraying apparatus, which is in particular a constituent part of the processing apparatus.

(11) FIG. 3 shows a flow diagram of a further embodiment of a method for the processing of a raw casting, wherein, in addition to the mere cooling of the raw casting, and in particular of a section of the raw casting, a straightening of the raw casting is also shown. The raw casting, after being produced in a cavity and, in particular, in a casting machine, is advantageously provided to the processing apparatus in the step S1. In the subsequent step S7, the raw casting is advantageously measured by way of a geometry measurement device, such that, for example, the length and/or width thereof, and/or the angle thereof and in particular the overall geometry thereof, can be measured. It is furthermore contemplated that, at least at times during the measurement of the raw casting or during the determination of at least one geometry value of the raw casting, the raw casting is rotated or moved within the measurement device in order to make it possible for individual regions or sections of the raw casting to be measured. It is, however, also contemplated for only the measurement devices or the at least one measurement device to be able to be moved along at least one section of the raw casting for the determination of the at least one geometry value. Accordingly, it is likewise possible for both the raw casting and the at least one measurement device to be able to be moved relative to one another.

(12) During the evaluation of the measurement data relating to the geometry of the raw casting by way of a comparison device, as shown in particular in step S8.1 in FIG. 3, it is advantageously possible, in parallel with or at the same time as the evaluation process or the process of the setpoint-actual value comparison, for the raw casting to be transported or transferred for example into a spraying apparatus, as shown in particular by step S8.2. Consequently, it is contemplated for the apparatus for the measurement of the geometry and the spraying apparatus to be apparatuses that are separate from one another, and between which the raw casting can be transferred for processing purposes. It is, however, also contemplated for the measurement apparatus and the spraying apparatus to constitute a common apparatus for the processing of the raw casting, such that the step S8.2 would consequently be omitted. The comparison device firstly evaluates the determined geometry values with regard to reference values that are advantageously stored in a memory device of the comparison device, and secondly checks, in a subsequent step S9, whether any determined geometry deviations lie within predefined tolerance ranges. If the determined or measured dimensions or geometries correspond to the predefined reference values, or if they lie within admissible tolerance thresholds, then in a subsequent step S3, the temperature and, in particular, the surface temperature of the raw casting is advantageously determined by way of a temperature measurement device. The determined temperature measurement values, which can also be referred to as temperature actual values, are in turn transmitted to the comparison device, which compares the received or measured temperature actual values with a corresponding reference value or temperature threshold value, and in particular a temperature setpoint value, in a step S4, wherein the one or more temperature threshold values is/are in turn advantageously stored in a memory device of the comparison device. If the measured temperature actual value is greater than a predefined temperature threshold value, at least a section, and advantageously individual sections, of the raw casting are acted on with the flowable medium, as shown in particular in step S2. It is advantageously the case that the temperature measurement by way of the temperature measurement device is in turn performed during or even after the action of the flowable medium on the raw casting, in order to make it possible to determine whether the temperature of the raw casting has reached the predefined temperature threshold value. Accordingly, it is advantageously the case that, during the action of the flowable medium on the raw casting, a continuous temperature measurement is performed, as illustrated by step S3, and a comparison of the determined temperature values with the stored temperature threshold value is performed, as shown in step S4, such that the attainment of the temperature threshold value can be determined in real time. If the comparison device determines that the temperature actual value has reached the temperature threshold value or lies below the temperature threshold value, the raw casting, and in particular the cooled raw casting, is advantageously removed from the spraying apparatus, as shown in step S5, and supplied for a deburring process for the coarse and fine deburring, wherein the deburring process itself may also be performed within the spraying apparatus.

(13) If the geometry measurement device determines a geometry or measurement deviation in the preceding step S8.1, wherein the determined measurement deviation furthermore does not lie within predefined tolerance thresholds, as shown in step S9, then a targeted action of the flowable medium on individual sections of the raw casting, as shown in step S10, is initiated. After the cooling or the spray cooling of the raw casting, the raw casting can again, as shown, for example, in step S11, be removed from the spraying apparatus and supplied to a measurement apparatus for the measurement of the geometry and determination of at least one geometry value of the raw casting. Consequently, step S11 would describe transportation of the raw casting. It is however also contemplated that, as already mentioned above, the measurement apparatus and the spraying apparatus form a common apparatus, such that transportation of the raw casting between the individual steps of measurement and cooling is not necessary. In this case, step S11 could be understood as handling of the raw casting after or at least also at times during the targeted action of the flowable medium on the individual sections of the raw casting, in such a way that said raw casting can for example be moved within the combined measurement and spraying apparatus and in particular rotated about a certain axis of rotation or longitudinal axis in different directions. In this case, step S11, and step S12 discussed below, would advantageously coincide.

(14) In step S12 in FIG. 3, it is for example the case that a geometry measurement by way of the geometry measurement device is in turn performed during and advantageously after the targeted impingement of the flowable medium on the raw casting, in order, in turn, to obtain geometry actual values, which are transmitted to the comparison device. This in turn performs, in a step S13.1, a setpoint-actual value comparison of the determined geometry values. During the evaluation of the data or measurement values, it is contemplated for the raw casting to be removed again from the measurement apparatus and transferred to a spraying apparatus, as shown in particular by step S13.2, which advantageously takes place at the same time as or in parallel with the step S13.1. However, if the measurement apparatus and the spraying apparatus are a common apparatus, then step S13.2 constitutes, in particular, handling of the casting, in the case of which, during the measurement and/or the evaluation of the measurement data, spray cooling and/or continuous measurement of the raw casting, and a determination of the geometry data thereof, are performed. If the determined geometry actual values correspond to the geometry setpoint values that are advantageously stored in a memory device, or if the determined geometry actual values lie within predefined tolerance thresholds, then the step S14 is followed by the step S3, as already described above, and consequently the temperature measurement by way of the temperature measurement device. Otherwise, in a step S15, it is determined whether at least one of possible rejection criteria is met. Rejection criteria are, for example, intense deformations, or regions or sections of the raw casting that have already cooled to too great an extent, such that the raw casting can no longer be straightened or processed by way of the flowable medium in order to produce a corresponding cast component. Consequently, the raw casting that can no longer be processed is rejected from the processing apparatus in a step S16 and supplied to a reject container, as shown by step S17. If the raw casting does not meet the rejection criteria, it continues to be acted on with the flowable medium in defined sections or regions, such that straightening of the component, as initiated by step S10, is continued.

(15) It is advantageously the case that, with the processing apparatus according to the invention and the method according to the invention for the processing and for the production of a cast component, a deburring step, and consequently a press and a punching tool, are omitted, because in particular, the coarse deburring and the fine deburring can be performed in one processing step after the cooling of the raw casting. Furthermore, it is advantageously the case that subsequent manual straightening of the parts is no longer necessary, in particular because straightening of the components can be performed by way of the flowable medium, which is also used for cooling purposes. Consequently, the transportation and storage costs are thus advantageously reduced.

LIST OF REFERENCE DESIGNATIONS

(16) 1 Processing apparatus 2 Spraying apparatus 3, 3.1-3.7 Nozzle device 4 Temperature measurement device 5 Geometry measurement device 6 Data communication line 7 Control device 10 Comparison device 10.1 Memory device 10.2 Evaluation device 20 Raw casting B Movement direction D Rotation direction Dx Rotation direction about X axis Dy Rotation direction about Y axis Dz Rotation direction about Z axis L Longitudinal axis M Flowable medium S1 Provision of the raw casting S2 Action of the flowable medium on the raw casting S3 Measurement of the temperature S4 Comparison of the temperature actual value with the temperature threshold value S5 Removal of the cooled raw casting S6 Deburring S7 Geometry measurement S8.1 Setpoint-actual value comparison S8.2 Handling of the raw casting S9 Comparison of the dimensional deviation with a predefined tolerance S10 Targeted action of the flowable medium on the raw casting S11 Handling of the raw casting S12 Geometry measurement S13.1 Setpoint-actual value comparison S13.2 Handling of the raw casting S14 Comparison of the determined dimensional deviation with respect to a predefined tolerance S15 Determination of whether at least one rejection criterion is met S16 Rejection of the casting S17 Rejects T Transport path X X axis Y Y axis Z axis

(17) The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.