TWI893535B - Casting system of flexible manufacturing process for piston - Google Patents

Abstract

A casting system of flexible manufacturing process for piston produces pistons through an integrated structure of a left-right mold unit, a central mold device, a left-right internal mold device, a cooling system, and a lift system that operate together. Using the aforementioned machine modules, each step is operated sequentially and consecutively as a secondary driving effect of a continuous manufacturing process in order to achieve a complete automation and mechanization with a continuous and consecutive manufacturing process of casting pistons. The machine further comprises a lifting mechanism that increases the adjusting margin of the equipment and the diversity of piston types to be manufactured, which is one key feature of the present invention.

Description

Casting system that allows flexible changes in piston manufacturing processes

This invention relates to an automated casting system for manufacturing pistons, specifically a casting system that allows for flexible changes in the piston manufacturing process. Pistons are manufactured through the collaborative operation of left and right mold assemblies, a center mold assembly, left and right inner mold assemblies, a cooling system, and a lifting system. The aforementioned tooling module sequentially provides a secondary drive for each step, resulting in a continuous process. This allows for fully automated, mechanized, continuous, and sustained piston casting. The tooling also includes a lifting mechanism for raising the center mold assembly and left and right inner mold assemblies. This significantly increases the equipment's range of motion and allows for a variety of piston manufacturing types.

Engine power is used in automobiles, motorcycles, generators, bulldozers, forklifts, drilling rigs, and many other applications. The power comes from the movement of the engine's pistons.

The finished piston production process must first cast the aluminum solution into a blank. This casting process was previously done manually, with two molds being controlled and closed on both sides of a bed. The two cores were then manually manipulated to merge the two bodies into the mold cavity, leaving a central portion free for a central core to be aligned with the hollow space of the two side cores and then inserted into the mold to form a complete body. After inspection, the mold diameter was checked. Maintaining an appropriate amount of space without imbalance, the aluminum solution is injected. When the formed blank is ready to be demolded, the previous steps are repeated one by one, with each step being divided into sections. The core block is removed in sequence. The center block opens the two molds, and a clamp is used to clamp the blank, remove it, and transfer it to the cooling process. This process is labor-intensive, time-consuming, and labor-intensive. Not only does it limit production and reduce quality, it also increases costs exponentially, making it uneconomical to operate.

Therefore, one manufacturer has developed an automated casting machine consisting of left and right mold assemblies, a central core device, left and right core devices, and a cooling system. The main features of the machine are that the left and right half-molds are assembled, the two cores are merged into the mold surface, and a central column core block is placed into the mold. Aluminum slurry is then poured into the casting to form the valve body blank. The blank can then be removed manually or by a robot.

However, the aforementioned automated casting machine has the following deficiencies:

1. The left and right mold assemblies, the center core device, and the left and right core devices are driven by pneumatic cylinders. Therefore, the stroke and distance of movement are limited. This limits the production of pistons of fixed specifications and prevents interchangeable production. For example, it can only produce pistons of a single specification for gasoline vehicles, limiting the application of the automatic casting machine.

2. As mentioned above, because the left and right mold assemblies, the center core device, and the left and right core devices are restricted by the location of the pneumatic cylinders, technicians have limited range of movement when setting up the mold, making it very easy for them to collide with the aforementioned equipment, posing a safety hazard.

The primary objective of this invention is to provide a casting system that allows for flexible piston manufacturing processes. This system utilizes a left and right mold assembly, a center mold assembly, left and right inner mold assemblies, a cooling system, and a lifting system to manufacture pistons. The aforementioned machine modules sequentially drive each step, achieving a continuous process. This allows for fully automated, mechanized, and continuous piston casting. The machine also includes a lifting mechanism that elevates the center mold assembly and left and right inner mold assemblies. This significantly increases the equipment's range of motion and allows for a variety of piston production types.

The reason is that the casting system of the elastically changeable piston process of the present invention basically includes: a machine, which includes a horizontally arranged bed portion, a forming table for forming is arranged in the center of the bed portion, and a plurality of column portions vertically arranged on the bed portion, and an upper frame is provided at the upper end of the column portion; a left and right mold unit, which is arranged on the bed portion of the machine, and the left and right mold units have two semicircular molds, and the back ends of the left and right mold units are respectively hinged with a pneumatic valve cylinder, and the pneumatic valve cylinders drive the semicircular molds in front to merge and form, and then merge the molds of the left and right mold units and cooperate with the forming table to form a closed circular mold body, and the circular mold body forms an opening along the top from the center; a central mold device, which is installed The center mold device is installed on the upper frame of the machine. The center mold device has a tapered center mold that penetrates the aforementioned circular mold body from top to bottom. The center of the center mold is connected to an upper pneumatic cylinder. The upper pneumatic cylinder pushes the center mold so that the center mold is extended and controlled in the aforementioned circular mold body to form and generate a retraction function to facilitate demolding; a left and right inner mold device, the left and right inner mold devices are installed on the upper frame of the machine. The left and right inner mold devices are respectively pushed forward or away from the center mold device along the upper frame through the inner mold pushing device. The aforementioned inner mold pushing device is provided with an inner mold lifting module in the direction of the center mold device, and an L-shaped lifting arm is provided on each of the inner mold lifting modules. The inner mold lifting module drives the L-shaped lifting arm The lower end of the L-shaped lifting arm is equipped with an inner mold. Each inner mold pushing device drives the L-shaped lifting arm toward the central mold device. The inner mold lifting module clamps the inner mold blocks at both ends of the central mold block. The central mold block and the inner mold blocks extend into the circular mold body to form a volume into which molten liquid metal can be injected. a cooling system, which is provided in the left and right mold units, and controls the temperature of the circular mold body through the cooling system, thereby cooling the molten liquid metal in the circular mold body to form; a lifting mechanism, which is installed at the upper end of the column portion and drives the upper frame to descend to form the circular mold body, or drives the upper frame to lift so that the central mold device, The left and right inner mold assemblies are separated from the circular mold body; a lowering mechanism is mounted at the lower end of the column. The lowering mechanism drives the bed down, allowing the left and right mold assemblies to open the molds via the pneumatic valve cylinders, or the lowering mechanism drives the bed up to perform the molding operation; and a control system is electrically connected to the left and right mold assemblies, the center mold assembly, the left and right inner mold assemblies, the cooling system, the lifting mechanism, and the lowering mechanism. The control system controls the merging or opening of the left and right mold assemblies, the merging or demolding of the center mold assembly and the left and right inner mold assemblies, the cooling of the cooling system, and the operation of the lifting mechanism and the lowering mechanism, thereby achieving automated and mechanized continuous completion of piston castings.

In an embodiment of the present invention, the forming table may be further provided with a wear-resistant ring, which is clamped by the aforementioned semicircular mold to form a wear-resistant portion at the bottom end of the piston casting to prevent metal friction.

In an embodiment of the present invention, the semicircular molds of the left and right mold assemblies further include a pair of half casting openings. When combined to form the circular mold body, a casting portion is formed at one end of the circular mold body for casting molten liquid metal.

In an embodiment of the present invention, the inner mold blocks of the left and right inner mold devices are further provided with a placement portion for placing a piston component, so that the piston casting is formed together with the piston component.

Based on the above description, the advantages and effects of this invention are briefly described as follows:

1. By utilizing the relative positioning of the lifting and lowering mechanisms on the column, the specifications of pistons produced by the automated casting machine are no longer limited by the machine platform. For example, when the bed is farther from the upper machine platform, taller pistons can be produced; conversely, shorter pistons can be produced. Therefore, pistons for gasoline and diesel vehicles, agricultural machinery, and power tools can all be manufactured using the equipment provided by this invention.

2. Utilizing a lifting and lowering mechanism, the machine's operating space is significantly increased, preventing accidents such as collisions between operators and the machine.

3. Because the lifting and lowering mechanisms are adjustable, piston production operations can be flexibly adjusted. For example, when there's a rush order, simply adjust the position of the bed and upper frame and install the upper semicircular mold to immediately produce the rush order. This provides production flexibility, enabling the ability to accept orders, produce, and ship at any time, increasing profitability.

10: Machine

11:Bed section

12: Molding table

13: Column

14: Mounting on the rack

20: Left and right module units

21, 21A: Semicircular mold

21B: Circular Phantom

21C: Open

22, 22A: Pneumatic valve cylinder

23, 23A: Casting Mouth

23B: Casting Department

30: Center mold device

31: Center Module

32: Upper air cylinder

40: Left and right inner mold devices

41, 41A: Inner mold pusher

42, 42A: Inner mold lifting module

43, 43A: L-shaped boom

44, 44A: Inner mold

441, 441A: Storage Unit

45: Piston parts

50: Cooling system

60: Lifting mechanism

70: Lowering mechanism

80: Control System

90: Wear-resistant ring

100: Piston castings

101: Piston castings

102: Wear-resistant part

Figure 1 is a system diagram of the present invention.

Figure 2 shows the merging of the semicircular molds of the left and right mold units.

Figure 3 is a structural diagram of the center mold device.

Figure 4 shows the structure of the left and right inner mold devices.

Figure 5 is a schematic diagram of the center module and inner module combined.

Figure 6 is a schematic diagram of the central module and inner module entering the circular mold body.

Figure 7 is a schematic diagram showing the operation of the left and right mold units, the center mold assembly, and the left and right inner mold assemblies.

Figure 8 is a schematic diagram of the operation of the left and right inner mold devices.

Figure 9 is a schematic diagram of the operation of the central mold device.

Figure 10 is a schematic diagram showing the operation of the left and right inner mold devices combined with the center mold device.

Figure 11 is a schematic diagram of the operation of the left and right module units.

Figure 12 is a schematic diagram of the bed platform being raised by the lowering mechanism.

Figure 13 is a schematic diagram of the central mold device extending into the circular mold body.

Figure 14 is a schematic diagram of the action of pouring molten liquid metal.

Figure 15 is a schematic diagram of the demolding of the center mold block of the center mold device.

Figures 16 and 17 are schematic diagrams of the left and right inner mold devices being demolded.

Figure 18 is a schematic diagram of the bed platform lowering operation.

Figure 19 is a schematic diagram of the upper rack rising.

Figure 20 is a system block diagram of the present invention.

Figure 21 is a schematic diagram of another implementation of Figure 2.

To help you gain a deeper understanding and appreciation of the features and advantages of this invention, we hereby provide a preferred embodiment with accompanying diagrams. Referring to Figures 1 to 20 , it can be seen that the flexible piston casting system of this invention primarily comprises: a machine 10 , a left and right mold assembly 20 , a center mold assembly 30 , left and right inner mold assemblies 40 , a cooling system 50 , a lifting mechanism 60 , a lowering mechanism 70 , and a control system 80 .

As shown in Figure 1, the machine 10 includes a horizontally arranged bed 11, a forming table 12 for forming is located in the center of the bed 11, and a plurality of vertical columns 13 are arranged on the bed 11. An upper frame 14 is located at the upper end of the columns 13.

As shown in Figures 1 and 2, the left and right mold assemblies 20 are arranged on the bed portion 11 of the machine 10. The left and right mold assemblies 20 have two semicircular molds 21 and 21A, each of which is hinged with a pneumatic valve cylinder 22 and 22A at its back end. The pneumatic valve cylinders 22 and 22A drive the front semicircular molds 21 and 21A to merge and form a closed circular mold body 21B by merging the semicircular molds 21 and 21A of the left and right mold assemblies 20 and cooperating with the forming table 12. The circular mold body 21B has an opening 21C formed from the center along the top. The semicircular molds 21 and 21A of the left and right mold assemblies 20 further include a pair of half casting openings 23 and 23A. When combined to form the circular mold body 21B, a casting portion 23B is formed at one end of the circular mold body 21B for casting molten liquid metal.

As shown in Figures 1 and 3, the center mold assembly 30 is mounted on the upper frame 14 of the machine 10. The center mold assembly 30 comprises a tapered center mold block 31 that extends downwardly into the circular mold body 21B. An upper pneumatic cylinder 32 is connected to the center of the center mold block 31. The upper pneumatic cylinder 32 pushes the center mold block 31, extending it into the circular mold body 21B and retracting it to facilitate demolding.

As shown in FIG1 and FIG4, the left and right inner mold devices 40 are mounted on the upper frame 14 of the machine 10. The left and right inner mold devices 40 are respectively pushed forward or away from the center mold device 30 along the upper frame 14 by the inner mold pushing devices 41 and 41A. The inner mold pushing devices 41 and 41A are provided with an inner mold lifting module 42 and 42A in the direction of the center mold device 30, and an L-shaped lifting arm 43 and 43A are provided on each inner mold lifting module 42 and 42A. The inner mold lifting modules 42 and 42A drive the L-shaped lifting arm 43 and 43A to move the inner mold lifting modules 42 and 42A. The arms 43 and 43A rise and fall, and an inner mold block 44 and 44A is provided at the lower end of the L-shaped lifting arm 43 and 43A. The inner mold pushing devices 41 and 41A drive the L-shaped lifting arms 43 and 43A toward the central mold device 30. Please refer to Figure 5. The aforementioned inner mold blocks 44 and 44A utilize the inner mold lifting modules 42 and 42A to clamp the inner mold blocks 44 and 44A at both ends of the central mold block 31. The central mold block 31 and the inner mold blocks 44 and 44A are extended into the circular mold body 21B to form a volume space into which molten liquid metal can be injected. The inner mold blocks 44 and 44A of the left and right inner mold assemblies 40 are further provided with a receiving portion 441 and 441A. The receiving portion 441 and 441A is used to receive a piston component 45, such as a metal sheet, so that the piston casting is formed together with the piston component 45.

As shown in Figure 1, the cooling system 50 is installed in the left and right mold units 20. The cooling system 50 controls the temperature of the circular mold 21B, thereby cooling and forming the molten liquid metal in the circular mold 21B.

As shown in Figure 1, the lifting mechanism 60 is mounted on the upper end of the column portion 13 and drives the upper frame 14 downward to form the circular mold body 21B, or drives the upper frame 14 upward to separate the central mold assembly 30 and the left and right inner mold assemblies 40 from the circular mold body 21B.

As shown in Figure 1, the lowering mechanism 70 is mounted on the lower end of the column 13. The lowering mechanism 70 lowers the bed 11, allowing the left and right mold assemblies 20 to open the molds via the pneumatic valve cylinders 22 and 22A, or to raise the bed 11 for molding.

As shown in Figure 1, the control system 80 is electrically connected to the aforementioned left and right mold assemblies 20, center mold assembly 30, left and right inner mold assemblies 40, cooling system 50, lifting mechanism 60, and lowering mechanism 70. The control system 80 controls the merging or opening of the left and right mold assemblies 20, the merging or demolding of the center mold assembly 30 and left and right inner mold assemblies 40, the cooling of the cooling system 50, and the operation of the lifting mechanism 60 and lowering mechanism 70, thereby achieving automated and mechanized continuous completion of the piston casting 100.

Figure 20 shows a system block diagram of the present invention, which facilitates understanding of the connection relationships between the various modules and devices of the present invention.

The above is an introduction to the various components of this invention. Next, we will introduce the most innovative process and most significant advantages of this invention for producing piston castings:

1. As shown in Figure 8, the L-shaped arms 43 and 43A of the left and right inner mold assemblies 40 are lowered via the inner mold lifting modules 42 and 42A.

2. As shown in Figure 9, the center mold assembly 30 drives the center mold block 31 downward via the upper pneumatic cylinder 32, and the center mold block 31 is positioned at the same height as the aforementioned inner mold blocks 44 and 44A.

3. As shown in Figure 10, the inner mold pushers 41 and 41A are used to merge the inner mold blocks 44 and 44A onto the sides of the center mold block 31 of the center mold assembly 30. The detailed steps described above can be coordinated with Figure 5. If necessary, the piston assembly 45 can be assembled into the respective placement portions 441 and 441A. Continuing with Figure 10, the upper frame 14 is then lowered to a fixed position via the lifting mechanism 60.

4. As shown in Figure 11, the pneumatic valve cylinders 22 and 22A drive the front semicircular molds 21 and 21A to merge and assemble. Referring to Figure 2, the semicircular molds 21 and 21A of the left and right mold assemblies 20 are combined and combined with the forming table 12 to form a closed circular mold body 21B.

5. As shown in Figure 12, the platform 11 is raised by the lowering mechanism 70.

6. As shown in Figure 13, the aforementioned center mold assembly 30 and left and right inner mold assemblies 40 extend into the circular mold body 21B of the left and right mold assemblies 20. The detailed structural operation is shown in Figures 6 and 7. The center mold block 31 is then further extended into the circular mold body 21B via the upper pneumatic cylinder 32, ensuring the precise positioning of the center mold block 31, inner mold blocks 44, 44A, and semicircular molds 21, 21A.

7. As shown in Figure 14, the molten metal is poured into the casting portion 23B formed by the casting nozzles 23 and 23A. Refer to Figure 1. The cooling system 50 then controls the temperature of the casting 21B, thereby cooling the molten metal in the casting 21B into shape.

8. As shown in Figure 15, after the molten liquid metal cools and forms, the center mold block 31 of the center mold assembly 30 is lifted and demolded by the upper air cylinder 32.

9. As shown in Figures 16 and 17, the left and right inner mold assemblies 40 are sequentially advanced toward the center mold assembly 30 by the inner mold pushing devices 41 and 41A. The inner mold lifting modules 42 and 42A then raise the L-shaped arms 43 and 43A slightly, and the inner mold pushing devices 41 and 41A then move away from the center mold assembly 30, thereby releasing the left and right inner mold assemblies 40 from the mold.

10. As shown in Figure 18, the bed platform 11 is lowered by the lowering mechanism 70.

11. As shown in Figure 19, the upper frame 14 is raised using the lifting mechanism 60.

12. As shown in Figure 1, the left and right mold assemblies 20 use pneumatic valve cylinders 22 and 22A to separate the front semicircular molds 21 and 21A, completing the piston casting 100.

13. As shown in Figure 21, when manufacturing a piston casting 101 for use in a diesel engine, the forming table 12 can be further provided with a wear-resistant ring 90. The wear-resistant ring 90 is clamped by the aforementioned semicircular molds 21 and 21A, so that a wear-resistant portion 102 is formed at the bottom end of the piston casting 101 to prevent friction with metal or fuel particles.

14. The present invention utilizes the relative positioning of the lifting mechanism 60 and the lowering mechanism 70 on the column portion 13, freeing the specifications of pistons produced by the automated casting machine from being limited by the machine platform. For example, when the bed portion 11 is farther from the upper platform 14, taller pistons can be produced; conversely, shorter pistons can be produced. Therefore, pistons for gasoline and diesel vehicles, agricultural machinery, and power tools can all be manufactured using the equipment provided by the present invention.

15. As shown in Figure 1, the use of a lifting mechanism 60 and a lowering mechanism 70 significantly increases the machine's operating space, preventing accidents such as workers colliding with the machine.

16. Because the lifting mechanism 60 and lowering mechanism 70 are positionally adjustable, piston production operations can be flexibly adjusted. For example, when a rush order arrives, the position of the bed 11 and upper frame 14 can be adjusted, and the upper semicircular molds 21 and 21A can be installed to immediately produce the rush order. This provides production flexibility, enabling the immediate acceptance of orders, production, and shipment, thereby increasing profitability.

17. The present invention can further be used in conjunction with a robotic arm to cast molten liquid metal, or to clamp the wear-resistant ring 90 onto the forming table 12, or to clamp the piston castings 100, 101, thereby achieving unmanned and automated functions.

In summary, the structure of this invention has not been found in any books or publications, nor has it been used publicly. It truly meets the requirements for an invention patent application. We sincerely request the Bureau to review this and grant the patent as soon as possible. We would be most grateful.

It should be noted that the above description is the specific implementation method and technical principles employed by the present invention. Any modifications based on the concept of the present invention that still produce functions within the spirit of the description and drawings should be stated within the scope of the present invention.

10: Machine 11: Bed 12: Forming table 13: Column 14: Upper frame 20: Left and right mold units 21, 21A: Semicircular mold 22, 22A: Pneumatic valve cylinder 30: Center mold assembly 31: Center mold block 32: Upper air cylinder 40: Left and right inner mold units 41, 41A: Inner mold pusher 42, 42A: Inner mold lifter 43, 43A: L-shaped lift arm 44, 44A: Inner mold block 50: Cooling system 60: Lifting mechanism 70: Lowering mechanism 80: Control system 100: Piston casting

Claims (5)

A casting system for a flexible piston manufacturing process comprises: A machine comprising a horizontally arranged bed, a forming table disposed in the center of the bed, and a plurality of vertical columns disposed on the bed, each with an upper frame disposed at its upper end; A left-right mold assembly, mounted on the bed of the machine. Each left-right mold assembly comprises two semicircular molds, each hinged to a pneumatic valve cylinder at its rear end. Each pneumatic valve cylinder drives the front semicircular molds to merge and form a closed circular mold body. A center mold assembly mounted on the upper frame of the machine. The center mold assembly comprises a tapered center mold block that extends downwardly into the circular mold body. An upper pneumatic cylinder is connected to the center of the center mold block, which is pushed by the upper pneumatic cylinder to extend the center mold block into the circular mold body and retract to facilitate demolding. Left and right inner mold assemblies are mounted on the upper frame of the machine. Each of the left and right inner mold assemblies is advanced or retreated along the upper frame toward the center mold assembly by an inner mold advancing assembly. The inner mold advancing assembly is provided with an inner mold lifting assembly facing the center mold assembly, and each inner mold lifting assembly is provided with an L-shaped lifting arm. The L-shaped lifting arm is driven by a lifting module. An inner mold block is installed at the lower end of the L-shaped lifting arm. Each inner mold pushing device drives the L-shaped lifting arm toward the central mold device. The inner mold lifting module clamps the inner mold blocks at both ends of the central mold block. The central mold block and each inner mold block extend into the circular mold body to form a volume into which molten liquid metal can be injected. A cooling system, mounted on the left and right mold assemblies, controls the temperature of the circular mold, thereby cooling and forming the molten metal within the circular mold. A lifting mechanism, mounted on the upper end of the column, drives the upper frame downward to form the circular mold, or drives the upper frame upward to separate the center mold assembly and the left and right inner mold assemblies from the circular mold. A lowering mechanism, mounted on the lower end of the column, drives the bed assembly downward to open the left and right mold assemblies via the pneumatic valve cylinders, or drives the bed assembly upward to form the mold. A control system is electrically connected to the aforementioned left and right mold assemblies, center mold assembly, left and right inner mold assemblies, cooling system, lifting mechanism, and lowering mechanism. The control system controls the merging or opening of the left and right mold assemblies, the merging or demolding of the center mold assembly and the left and right inner mold assemblies, the cooling of the cooling system, and the operation of the lifting mechanism and lowering mechanism, thereby achieving automated and mechanized continuous completion of a piston casting. According to claim 1, a casting system capable of flexibly changing a piston manufacturing process is provided, wherein the circular mold body forms an opening from the center along the top. According to the casting system for flexibly changing the piston manufacturing process described in claim 1, the forming table can be further provided with a wear-resistant ring, which is clamped by the aforementioned semicircular mold so that the bottom end of the piston casting forms a wear-resistant portion to prevent metal friction. According to the casting system with flexible change of piston manufacturing process described in claim 1, the semicircular mold of the left and right mold units further includes a pair of half casting openings. When combined into the circular mold body, a casting portion capable of casting molten liquid metal is formed at one end of the circular mold body. According to the casting system with flexible change of piston manufacturing process described in claim 1, the inner mold blocks of the left and right inner mold devices are further provided with a placement portion, which is used to place a piston part, so that the piston casting product is formed together with the piston part.