Casting is one of the fundamental processes in modern manufacturing industry and plays an indispensable and important role in the development of the national economy. Automated casting production line refers to a production line that uses intelligent robots to concentrate multiple casting processes on the same automated assembly line for production and processing. It is different from traditional casting production lines that rely heavily on manual labor and have separate specific processing procedures. Intelligent casting production lines have the characteristics of highly centralized processes, mixed line production, multi robot collaboration, and high intelligence, which can improve casting production The level of automation and intelligence in production lines is of great significance. Due to the concentration of production line processes, most operations are completed by intelligent robots alone or in collaboration. In the process, the handling of sand cores or castings is completed by heavy-duty robots, which can simplify the point-to-point trajectory planning problem of robots. The handling of multiple varieties and large quantities of sand cores or castings results in a wide range of changes in the end load mass of the robot, posing significant challenges to the robot’s motion control; At the same time, even if the end effector of the robot is flexible, Multiple sets of fixtures are also required to meet the mixed production needs of the casting production line. Based on the characteristics of mixed flow and mixing in the casting production line of key engine components, in order to transform the casting production line from mechanization operated by workers to robotics and intelligence, it is necessary to study the casting process, casting operation robots, casting process information, and independently develop an intelligent casting robot production line. Regarding sand molding, sand core making, and sampling We have completed the key technical solution design for a series of manufacturing processes, including core, coating, dipping, gluing, core assembly, core placement, box closing, and post-processing. Based on the characteristics and requirements of different processes, we have integrated the development of robot applications and established a multi process robot automated production line for mixed production of multiple models and batches of engine components. We have also planned the process flow and layout of the production line to meet the quality and efficiency requirements of the casting production process. Realizing automation and intelligence of casting production lines is essential for improving production efficiency An important way to improve production efficiency and ensure product quality. In recent years, with the rapid development of artificial intelligence technology and robotics technology, the conditions for achieving automation in casting production have been basically met. However, due to the numerous processes, complex craftsmanship, high requirements, and harsh on-site environment of the casting production line, robots used in automated casting production lines have a series of problems such as poor functional implementation quality, poor coordination, and frequent errors. At present, the application of robots in automated casting production lines is still not very successful. A deep understanding of the process flow and characteristics of automated casting production lines is an important foundation for promoting the application of robots in the casting industry and truly realizing the automation and intelligence of casting production. In order to achieve the above goals, this article analyzes in detail the process and technical requirements of the intelligent casting production line, and further focuses on discussing the handling operations that exist in multiple important processes. Summarized the issues that need to be considered when designing an automated robot casting production line.
The sand core immersion coating is one of the most important processes in the casting production line. The characteristics of immersion coating are high production efficiency, simple operation, and minimal coating loss.
(1) Sand core grabbing. The sand core is transported to the immersion coating process through a tray conveyor belt. Due to the lack of a positioning device, the robot needs to accurately position and adjust its posture before grasping the sand core to ensure the accuracy of the grasping path. Robots need to apply force reasonably according to the material and structural characteristics of the sand core when grasping it, in order to avoid damaging the sand core. Therefore, the key process parameters involved in sand core grasping include: sand core spatial position, robot spatial position and grasping posture, sand core grasping force, sand core grasping speed, etc.
(2) Move to above the immersion pool. Considering the on-site environment and efficiency, it is necessary to plan the spatial trajectory of the robot grasping the sand core and moving it above the immersion tank. It is also necessary to consider the balance between the stability and speed of the sand core. If the movement speed is too fast, the sand core will shake greatly and the stability will be poor; On the contrary, sand cores have good stability but low efficiency. Therefore, the key process parameters of this process are the robot’s spatial motion path and spatial motion speed.
(3) Sand core immersion coating. Sand core immersion coating refers to the three basic actions of the robot driving the sand core downwards into the immersion coating pool, stopping, and exiting the immersion coating pool. During the process of sand core immersion, there are requirements for the immersion speed. A fast immersion speed can easily cause paint splashing, while a low immersion speed can result in low efficiency. There are requirements for the depth and residence time of sand core immersion in the immersion pool, which are related to the type of sand core and the coating material. The main purpose of exiting the immersion coating tank is to control the speed and the height of the sand core above the liquid surface after exiting the immersion coating tank. The lifting rate is fast and the paint film is thin; Slow improvement rate, thick and uneven paint film.
(4) The sand core swings. After lifting the sand core, in order to remove excess paint, swing the sand core to shake off the excess paint. The frequency and amplitude of oscillation affect the coating effect.
(5) Move above the placement point.
(6) Sand core release. Moving to the tray means swinging and then moving to the tray to prepare for feeding. The content of this process research is the movement speed, and it is necessary to find the appropriate movement speed.
(7) The robot returns to its original position. The robot returns to the origin and enters the next cycle. The content of this process research is the speed of movement, which needs to be found Provide appropriate movement speed.
The sand core is a key component for achieving the cavity structure during the casting process. The traditional sand core assembly method requires manual operation, which is cumbersome, inefficient, and difficult to guarantee quality. Pouring process refers to the manufacturing process of pouring molten metal or alloy into sand or metal molds during the casting process to form the desired castings. Casting demolding: After the casting is completely cooled and solidified, the robot can remove it from the sand or metal mold. For sand molds, tapping or vibration can be used to separate the sand core from the casting; For metal molds, castings can be removed through methods such as cracking, melting, or disassembly. Almost all process steps in the casting production line require the involvement of handling operations. In the processes of core picking, core assembly, and dip coating, the handling operation is located between two processes, connecting the two processes, thus requiring a production cycle for the handling operation; In the casting polishing process, the handling operation is also Has heavy load characteristics. The production rhythm has strict requirements for the movement time of robots during task execution, and heavy load conditions can cause robots to easily vibrate during and after movement. The human casting process can achieve continuous, high-speed, and accurate operation, greatly improving production efficiency. Robots can complete the pouring and subsequent processing of a large number of castings in a short period of time, reducing production cycles and costs.
The overall process flow of the casting production line. Emphasis was placed on discussing important processes such as casting immersion coating and casting polishing, and key process parameters were provided. Due to the ubiquitous nature of handling operations in automated casting production, this article concludes with a focused analysis of handling operations. The application of intelligent robots in casting production lines effectively reduces the manpower input in the production process. The advantage of automation makes the casting production process more efficient and stable. Robots can work continuously for 24 hours, greatly improving the production capacity and stability of the production line, Thus meeting the market’s demand for large quantities of high-quality products. The application of intelligent robots in casting production lines has brought revolutionary changes to the casting industry. It improves production efficiency, product quality, and production line flexibility, reduces labor intensity, and provides strong support for the sustainable development of the industry. In the process of promoting the application of robots, we need to carefully address relevant technical, economic, and social issues to ensure the robust application of robots and achieve optimal results in human-machine collaboration. In the future, we have reason to believe that robot technology will continue to drive the foundry industry towards more intelligent, efficient, and sustainable development.