MOLDING SYSTEM AND MOLDING METHOD

Abstract

A molding system includes a flaskless molding machine configured to mold a cope and a drag and to push out the cope and the drag onto a surface plate bogie positioned at a mold pushing position among a plurality of surface plate bogies being conveyed, and a jacket covering device configured to cover the cope and the drag on the surface plate bogie at the mold pushing position with a jacket.

Claims

1. A molding system comprising: a flaskless molding machine configured to mold a cope and a drag and to push out the cope and the drag onto a surface plate bogie positioned at a mold pushing position among a plurality of surface plate bogies being conveyed; and a jacket covering device configured to cover the cope and the drag on the surface plate bogie at the mold pushing position with a jacket.

2. The molding system according to claim 1, wherein the jacket covering device is configured to cover the cope and the drag with the jacket and place a weight on the cope and the drag.

3. The molding system according to claim 2, further comprising a weight cleaning device disposed on an upstream side of the flaskless molding machine in a conveying direction of the plurality of surface plate bogies and configured to clean the weight.

4. The molding system according to claim 1, further comprising a jacket cleaning device disposed on an upstream side of the flaskless molding machine in a conveying direction of the plurality of surface plate bogies and configured to clean an inner surface of the jacket.

5. The molding system according to claim 2, further comprising: a conveying device configured to convey the plurality of surface plate bogies; and a control unit connected to the conveying device and the flaskless molding machine, wherein the control unit is configured to generate shift data associating conveying positions with mold-related information, and associate data of at least one of the surface plate bogies, the jacket, and the weight with the shift data.

6. A molding method comprising: molding a cope and a drag and pushing out the cope and the drag onto a surface plate bogie positioned at a mold pushing position among a plurality of surface plate bogies being conveyed; and covering the cope and the drag on the surface plate bogie at the mold pushing position with a jacket.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a top view schematically showing an example of a configuration of a casting facility including a molding system according to an embodiment.

[0009] FIG. 2 is a front view schematically showing an example of the configuration of the casting facility shown in FIG. 1.

[0010] FIGS. 3A, 3B, 3C and 3D are diagrams for explaining an operation of a first jacket lifter at a mold pushing position.

[0011] FIGS. 4A, 4B, 4C, 4D, 4E and 4F are diagrams for explaining operations of a second jacket lifter and a weight lifter at a shake-out position.

DETAILED DESCRIPTION

[0012] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant descriptions are omitted. The dimensional ratios in the drawings do not necessarily match those in the description. The words upper, lower, left, and right are based on the illustrated state and are used for convenience. In the drawings, the X direction and the Y direction are horizontal directions, and the Z direction is a vertical direction.

[0013] FIG. 1 is a top view schematically showing an example of a configuration of a casting facility including a molding system according to an embodiment. FIG. 2 is a front view schematically showing an example of the configuration of the casting facility shown in FIG. 1. A casting facility 100 shown in FIGS. 1 and 2 is a facility for manufacturing cast products and is installed in a foundry or the like. The casting facility 100 includes a molding system 1 and a pouring apparatus 2. The molding system 1 includes a series of devices involved in a molding process. In the casting facility 100, a mold is molded by the molding system 1, conveyed to the pouring apparatus 2, and poured. The poured mold is shaken out after cooling, and a cast product is taken out.

[0014] As shown in FIGS. 1 and 2, the molding system 1 includes a molding machine 10. The molding machine 10 is a flaskless molding machine and molds a mold by squeezing foundry sand. The molding machine 10 is communicably connected to a control unit 11. The molding machine 10 starts molding in response to receiving a molding start signal from the control unit 11. The molding machine 10 throws foundry sand into a flask in which a pattern is placed, and compresses and squeezes the sand in the flask. The molding machine 10 obtains a mold by removing the pattern from the squeezed sand. The molding machine 10 molds a cope and a drag, respectively, and assembles the cope and the drag to form a cope and drag M. The molding machine 10 pushes out the cope and drag M with a cylinder or the like and delivers it to a conveying line. The molding machine 10 transmits a signal indicating that the cope and drag M has been delivered to the control unit 11.

[0015] The conveying line is a facility for conveying the cope and drag M. The conveying line receives the cope and drag M from the molding machine 10 and conveys the cope and drag M toward the pouring apparatus 2 downstream in a conveying direction. The conveying line has, for example, a rail and a plurality of surface plate bogies B that travel on the rail. The conveying line places and conveys the cope and drag M on each of the plurality of surface plate bogies B. The cope and drag M is pushed out onto a surface plate bogie positioned at a mold pushing position among the plurality of surface plate bogies B. The mold pushing position is a position where the molding machine 10 delivers the cope and drag M to the conveying line, and is, for example, a position P0 facing the molding machine 10.

[0016] The molding system 1 includes a first jacket lifter 12 (an example of a jacket covering device). The first jacket lifter 12 covers the cope and drag M with a jacket J. The jacket J is a frame body having an inner surface. The inner surface of the jacket J has the same inclination as the inclination of the side surfaces of the cope and drag M, and is in close contact with the side surfaces of the cope and drag M. This suppresses the occurrence of misalignment between the cope and the drag due to impacts during conveyance of the cope and drag M. In addition, collapse or lifting of the cope during pouring is suppressed.

[0017] The first jacket lifter 12 is a device that moves the jacket J up and down. The first jacket lifter 12 includes, for example, a lifting/lowering mechanism and a plurality of arms. The lifting/lowering mechanism is a drive mechanism such as a cylinder or an electric motor, and moves the plurality of arms up and down. The plurality of arms include a clamping mechanism for holding the jacket J. The first jacket lifter 12 covers the cope and drag M on the surface plate bogie positioned at the mold pushing position with the jacket J. The first jacket lifter 12 is disposed, for example, above the position P0, waits with the jacket J lifted before the cope and drag M is pushed out, and in response to the cope and drag M being pushed out onto the surface plate bogie, lowers the jacket J and covers the cope and drag M with the jacket J.

[0018] The first jacket lifter 12 may move a weight W up and down together with the jacket J. The weight W is a heavy object placed on the cope and drag. By using the weight W, lifting of the cope during pouring is suppressed. The first jacket lifter 12 can cover the cope and drag M with the jacket J and place the weight W on the cope and drag M by moving the jacket J up and down with the weight W and the jacket J stacked. The weight W may not be used depending on the required quality of the cast product. Details of the operation of the first jacket lifter 12 will be described later. Hereinafter, a surface plate bogie on which a cope and drag M before pouring is placed and on which a jacket J and a weight W are arranged on the cope and drag M is referred to as a surface plate bogie in a state T1.

[0019] The plurality of surface plate bogies B are arranged, for example, at equal intervals on a rail. The plurality of surface plate bogies B are conveyed by a predetermined number of molds by an intermittent drive. The predetermined number of molds may be one mold or a plurality of molds. Each of the surface plate bogies is conveyed in the X direction by a first conveying device 13 (an example of a conveying device) and a second conveying device 14 (an example of a conveying device). The first conveying device 13 is a pusher device or the like provided at one end of the rail, and the second conveying device 14 is a cushion device or the like provided at the other end of the rail. The conveying line is communicably connected to the control unit 11. The conveying line conveys the plurality of surface plate bogies B by a predetermined number of molds in response to receiving a mold conveying signal from the control unit 11. When the conveyance by the predetermined number of molds is completed, the conveying line transmits a mold conveying completion signal to the control unit 11.

[0020] The surface plate bogie in the state T1 arrives at a pouring zone where a pouring apparatus 2 is disposed by the conveying line. The pouring apparatus 2 is a device for pouring molten metal into the cope and drag M, and includes, for example, a nozzle for injecting molten metal into the cope and drag M. The pouring apparatus 2 is communicably connected to the control unit 11. The pouring apparatus 2 pours molten metal into the cope and drag M related to the surface plate bogie in the state T1 in response to receiving a pouring signal from the control unit 11. Hereinafter, a surface plate bogie on which a cope and drag M after pouring is placed and on which a jacket J and a weight W are arranged on the cope and drag M is referred to as a surface plate bogie in a state T2.

[0021] The surface plate bogie in the state T2 is moved to a cooling lane for cooling the molten metal. The cooling lane is provided below a casting lane where the processes of molding, pouring, and shake-out are performed. The casting lane and the cooling lane may be arranged side by side in an XY plane, as well as being arranged one above the other. The surface plate bogie in the state T2 is moved to a lower (first floor) cooling lane by a first lifter 15 (an example of a conveying device). In the cooling lane, each of the surface plate bogies in the state T2 is conveyed in the Y direction by a third conveying device 16 (an example of a conveying device) and a fourth conveying device 17 (an example of a conveying device). The third conveying device 16 is a pusher device or the like provided at one end of the rail, and the fourth conveying device 17 is a cushion device or the like provided at the other end of the rail. The surface plate bogie in the state T2 is moved to an upper (second floor) casting lane by a second lifter 18 (an example of a conveying device). As a result, the surface plate bogie in the state T2 moves to the upstream of the molding machine 10 in the casting lane.

[0022] The surface plate bogie in the state T2 arrives at a shake-out zone where a shake-out device 24 is disposed by the conveying line. The shake-out device 24 is a device for taking out a cast product from the cope and drag M. The shake-out device 24 is communicably connected to the control unit 11. The shake-out device 24 starts shake-out in response to receiving a shake-out start signal from the control unit 11. When the surface plate bogie in the state T2 arrives at a position P39, the weight W on the surface plate bogie is lifted by a weight lifter 19. The weight lifter 19 is a device that moves the weight W up and down. The weight lifter 19 includes, for example, a lifting/lowering mechanism and a plurality of arms. The lifting/lowering mechanism is a drive mechanism such as a cylinder or an electric motor, and moves the plurality of arms up and down. The plurality of arms include a clamping mechanism for holding the weight W. Details of the operation of the weight lifter 19 will be described later.

[0023] The weight W lifted by the weight lifter 19 is cleaned by a weight cleaning device 20. The weight cleaning device 20 is a device for cleaning an upper surface or a lower surface of the weight W, and includes, for example, a scraper and/or a brush. The scraper has a blade for removing sand and foreign matter adhering to the upper or lower surface of the weight W, and the brush has bristles for removing fine sand. The weight cleaning device 20 may also include an air blow.

[0024] Subsequently, the surface plate bogie is moved in the Y direction by a conveying device 21 such as a traverser. As a result, the cope and drag M from which the weight W has been removed is conveyed to a position where a second jacket lifter 22 is disposed. The second jacket lifter 22 removes the jacket J from the cope and drag M on the surface plate bogie. The second jacket lifter 22 includes, for example, a lifting/lowering mechanism and a plurality of arms. The lifting/lowering mechanism is a drive mechanism such as a cylinder or an electric motor, and moves the plurality of arms up and down. The plurality of arms include a clamping mechanism for holding the jacket J. Details of the operation of the second jacket lifter 22 will be described later.

[0025] The jacket J lifted by the second jacket lifter 22 is cleaned by a jacket cleaning device 23. The jacket cleaning device 23 is a device for cleaning an inner surface or an outer surface of the jacket J, and includes, for example, a scraper and/or a brush. The jacket cleaning device 23 may also include an air blow.

[0026] The cope and drag M from which the jacket J and the weight W have been removed is delivered from the surface plate bogie to the shake-out device 24. The jacket J and the weight W are returned to the emptied surface plate bogie. Hereinafter, a surface plate bogie on which a jacket J and a weight W are arranged is referred to as a surface plate bogie in a state T3. When the surface plate bogie in the state T3 reaches the position P0, which is the mold pushing position, the jacket J and the weight W are lifted by the first jacket lifter 12. As a result, the surface plate bogie becomes ready to receive a cope and drag M. With the configuration and operation described above, the pair of the surface plate bogie, the jacket J, and the weight W remains unchanged and the same. Since the pair of the surface plate bogie, the jacket J, and the weight W is invariable, tracking of manufacturing history becomes easy, and quality control and traceability are improved. In addition, by streamlining maintenance and stabilizing the production process, manufacturing costs can be reduced and product quality can be stabilized.

[0027] The control unit 11 is a device that supervises the casting process of the casting facility 100. The control unit 11 is configured, for example, as a PLC (Programmable Logic Controller). The control unit 11 may be configured as a computer system including a processor such as a CPU (Central Processing Unit), memory such as RAM (Random Access Memory) and ROM (Read Only Memory), input/output devices such as a touch panel, a mouse, a keyboard, and a display, and a communication device such as a network card.

[0028] The control unit 11 associates information related to molding with a cope and drag M (e.g., a mold identifier) as shift data. The shift data is associated with position information in a mold line, and is shifted in accordance with the movement each time a mold is moved (conveyed). To be shifted means to shift the association with the position information in the mold line. For example, when a cope and drag M1 is manufactured and pushed out, the cope and drag M1 and the position P0 are associated and stored. Subsequently, when a cope and drag M2 is manufactured and pushed out, the cope and drag M2 and the position P0 are associated and stored, and for the cope and drag M1, the position is shifted and associated with a position P1 and stored. In this way, the control unit 11 can manage the cope and drag M and the positions by associating them on data.

[0029] The control unit 11 may manage the pair of the surface plate bogie, the jacket J, and the weight W using the shift data. For example, an RFID (Radio Frequency Identification) tag is attached to each surface plate bogie, and the control unit 11 associates information of the pair read from the RFID tag by a reader with the shift data and stores it in a storage device of the control unit 11. The RFID tag may be provided on either the jacket J or the weight W. The RFID tag may be a two-dimensional code. Alternatively, the control unit 11 may associate the information of the pair read from the RFID tag by the reader with the shift data and write it to the RFID tag. Alternatively, the control unit 11 may virtually assign numbers to the surface plate bogies in advance, grasp the number of the surface plate bogie that has received the cope and drag M on data each time one mold is conveyed, and associate the grasped number with the shift data. The control unit 11 may associate only one surface plate bogie with the shift data and identify other surface plate bogies based on the number of conveyed molds.

[0030] FIGS. 3A, 3B, 3C and 3D are diagrams for explaining an operation of a first jacket lifter at a mold pushing position. As shown in FIG. 3A, a surface plate bogie B1 in a state T3 is conveyed to a position P0, which is below the first jacket lifter 12, that is, the mold pushing position. A jacket J1 and a weight W1 are placed on the surface plate bogie B1. Subsequently, as shown in FIG. 3B, the jacket J1 and the weight W1 are lifted from the surface plate bogie B1 by the first jacket lifter 12. As a result, the surface plate bogie B1 becomes empty. Subsequently, as shown in FIG. 3C, a cope and drag M1 is pushed out onto the surface plate bogie B1 by the molding machine 10. Subsequently, as shown in FIG. 3D, the cope and drag M1 on the surface plate bogie B1 is covered with the jacket J1 and the weight W1 is placed on it. In this way, since the cope and drag M1 is covered with the jacket J and the weight W1 is placed on it before the surface plate bogie B1 starts to move, misalignment of the cope and the drag due to the impact of conveyance can be avoided.

[0031] FIGS. 4A, 4B, 4C, 4D, 4E and 4F are diagrams for explaining operations of a second jacket lifter and a weight lifter at a shake-out position. The shake-out position includes both a position below the second jacket lifter 22 and a position P39 (see FIG. 2) below the weight lifter 19. As shown in FIG. 4A, a surface plate bogie B1 in a state T2 is conveyed to the position P39 below the weight lifter 19. A cope and drag M1, a jacket J1, and a weight W1 are placed on the surface plate bogie B1. Subsequently, as shown in FIG. 4B, the weight W1 is lifted from the cope and drag M1 by the weight lifter 19. Then, the upper surface and/or the lower surface of the weight W1 is cleaned by the weight cleaning device 20. Subsequently, as shown in FIG. 4C, the surface plate bogie B1 is conveyed in the Y direction and placed below the second jacket lifter 22. Then, the jacket J1 is removed from the cope and drag M1 by the second jacket lifter 22. Then, the inner surface and/or the outer surface of the jacket J1 is cleaned by the jacket cleaning device 23. Subsequently, as shown in FIG. 4D, the cope and drag M1 is delivered from the surface plate bogie B1 to the shake-out device 24. As a result, the surface plate bogie B1 becomes empty. Subsequently, as shown in FIG. 4E, the jacket J1 is placed on the surface plate bogie B1. Subsequently, as shown in FIG. 4F, the weight W1 is placed on the jacket J1. In this way, by cleaning the jacket J1 and the weight W1 on the upstream side of the molding machine 10, the quality of the cast product can be improved.

Summary of Embodiment

[0032] In the molding system 1, the cope and drag M on the surface plate bogie positioned at the position P0, which is the mold pushing position, is covered with the jacket J. Therefore, it is not necessary to arrange a device for covering with the jacket J so as to straddle lanes. Thus, the molding system 1 can improve flexibility in layout in the casting facility 100 related to flaskless molding. In addition, the movement of the surface plate bogie is started after covering with the jacket J. Therefore, the molding system 1 can avoid misalignment of the cope and the drag due to the impact of conveyance. Furthermore, when a device for covering with the jacket J is arranged so as to straddle lanes, not only the center alignment between the molding machine 10 and the conveying line but also the center alignment between the device for covering with the jacket J and the conveying line is required. In contrast, since the molding system 1 covers with the jacket J at the pushing position of the molding machine 10, it is sufficient to perform alignment between the molding machine 10 and the conveying line, and the number of alignments is sufficient at one time. Therefore, the molding system 1 can improve the efficiency of manufacturing cast products.

Modifications

[0033] Although various exemplary embodiments have been described above, the present disclosure is not limited to the above-described exemplary embodiments, and various omissions, substitutions, and changes may be made. For example, the first jacket lifter 12 does not need to be integrated with the molding machine 10. That is, the first jacket lifter 12 may include a dedicated frame and be supported by the dedicated frame.

Summary of Embodiments of the Present Disclosure

[0034] The present disclosure includes the following aspects.

[0035] (Clause 1) A molding system includes: a flaskless molding machine configured to mold a cope and a drag and to push out the cope and the drag onto a surface plate bogie positioned at a mold pushing position among a plurality of surface plate bogies being conveyed; and a jacket covering device configured to cover the cope and the drag on the surface plate bogie at the mold pushing position with a jacket.

[0036] In this molding system, the cope and the drag on the surface plate bogie positioned at the mold pushing position are covered with a jacket. Therefore, it is not necessary to arrange a device for covering with the jacket J so as to straddle lanes. Thus, the molding system can improve flexibility in layout in a casting facility related to flaskless molding. In addition, the movement of the surface plate bogie is started after covering with the jacket. Therefore, misalignment of the cope and the drag due to the impact of conveyance can be avoided.

[0037] (Clause 2) In the molding system according to Clause 1, the jacket covering device may cover the cope and the drag with the jacket and place a weight on the cope and the drag. In this case, the jacket and the weight can be applied to the cope and the drag simultaneously.

[0038] (Clause 3) The molding system according to Clause 1 or 2 may further include a weight cleaning device disposed on an upstream side of the flaskless molding machine in a conveying direction of the plurality of surface plate bogies and configured to clean the weight. In this case, the molding system can apply the cleaned weight to the cope and the drag immediately after molding.

[0039] (Clause 4) The molding system according to any one of Clauses 1 to 3 may further include a jacket cleaning device disposed on an upstream side of the flaskless molding machine in a conveying direction of the plurality of surface plate bogies and configured to clean an inner surface of the jacket. In this case, the molding system can apply the cleaned jacket to the cope and the drag immediately after molding.

[0040] (Clause 5) The molding system according to any one of Clauses 1 to 4 may further include: a conveying device configured to convey the plurality of surface plate bogies; and a control unit connected to the conveying device and the flaskless molding machine, wherein the control unit may generate shift data associating conveying positions with mold-related information, and associate data of at least one of the surface plate bogie, the jacket, and the weight with the shift data. In this case, since at least one of the surface plate bogie, the jacket, and the weight is easily identified, the molding system can promptly provide information effective for countermeasures against defects.

[0041] (Clause 6) A molding method according to another aspect of the present disclosure includes: molding a cope and a drag and pushing out the cope and the drag onto a surface plate bogie positioned at a mold pushing position among a plurality of surface plate bogies being conveyed; and covering the cope and the drag on the surface plate bogie at the mold pushing position with a jacket. This molding method provides the same effects as the molding system described above.