First, the development status of casting robots
Casting is one of the main methods for obtaining blanks of mechanical products, and is an important basic process in the mechanical industry. China's foundry industry is labor intensive, the overall technical level and equipment are backward, the casting quality is low, the materials and energy consumption are high, the working conditions are bad, and the pollution is serious. In recent years, the state has paid special attention to the environment and energy consumption. As a major resource consumption and environmental pollution, the foundry industry has encountered unprecedented challenges. Therefore, as a modern enterprise, the sustainable development of the foundry industry is a new mode of organization, management and operation. Green casting is valued and promoted by more and more enterprises.
Industrial robot is an important automation equipment for modern manufacturing industry integrating mechanical, electronic, control, computer, sensor and artificial intelligence. It has many advantages that traditional equipment does not have, and it is highly flexible to meet modern green casting. Various special requirements in production are increasingly used in casting. At present, the use of advanced and applicable new casting technology to improve the automation of casting equipment, especially the application of industrial robot automation technology, is a key measure for foundry enterprises to implement green casting production and achieve sustainable development. China is a big casting country, and industrial robots will definitely show their talents in the field of casting.
Due to the harsh environment of high temperature, high dust, vibration, oil pollution, noise and electromagnetic interference, the castings are not only high in temperature, but also heavy in weight, so a moving industrial robot cannot meet the production needs. The cast version of the industrial robot must be able to adapt to such a working environment and operate normally, which is a big challenge for manufacturers. At present, domestic companies involved in research and development of robots have sprung up, but there are few for the foundry industry. With its rich casting experience and leading technology of domestic foundry equipment, Wanfeng Technology applies industrial robots to the foundry automation project, which is a qualitative breakthrough for the domestic foundry industry equipment level. The accumulation of experience in many years of automation projects has resulted in the successful development of Wanfeng Technology's casting robots (multiple series, partially offsetting the industry gap) and has been widely used in the foundry industry.
Second, the application of industrial robots in the foundry industry
In casting production, industrial robots can not only replace people in high temperature, pollution and hazardous environments, but also improve work efficiency, improve product accuracy and quality, reduce costs, reduce waste, and obtain flexible and long-lasting high-speed production processes. . Wanfeng Technology combines casting technology, casting equipment and industrial robots, and continuously researches and develops project applications in the casting field. It has covered various fields such as die casting, gravity casting, low pressure casting and sand casting, mainly involving core making, sculpt, cleaning and machining. , inspection, surface treatment, transfer and palletizing.
The foundry is particularly prominent, filled with high temperatures, dust, noise, etc., and the working environment is extremely harsh. Industrial robots can be applied to gravity casting, low pressure casting, high pressure casting, and spin casting, covering ferrous and non-ferrous metal casting workshops with different casting methods, greatly reducing the labor intensity of employees.
Gravity casting
The traditional casting mode of gravity casting is artificial pouring of aluminum liquid, high temperature and high handling strength, especially for large castings requiring two spoons of aluminum pouring. This mode may result in poor casting process stability due to limitations of the operator's acceptor energy, and fluctuations in the quality of the cast product. Not only can manpower not be eaten, but quality is also affected. With the industrial robot pouring, the robot pouring management software automatically controls the robot according to the set casting process, and the product repeatability is consistent, which greatly improves the product quality and liberates the labor force.
According to the casting characteristics, the industrial robot gravity casting automation unit has a variety of layout formats.
(1) The circumferential type is suitable for castings with many product specifications, simple casting and small products. Each gravity machine can cast different specifications of products, the process beat can be diversified, one person can operate two gravity machines, due to fewer restrictions, It is the most commonly used mode at present, as shown in Figure 1.
Figure 1 Centrifugal industrial robot gravity casting automation unit
A single-phase VFD, also known as a variable frequency drive, is a specialized electronic device used for precise control and regulation of single-phase motors. Unlike three-phase motors that are commonly used in industrial applications, single-phase motors are predominantly found in residential and small-scale applications.
The primary function of a single-phase VFD is to control the frequency and voltage supplied to the single-phase motor, thereby enabling accurate regulation of motor speed. By adjusting the frequency and voltage output, the VFD allows for smooth and precise control over the motor's rotational speed. This feature is particularly useful in applications where speed control is required, such as in residential HVAC systems, small-scale machinery, and household appliances.
Energy efficiency is a significant advantage offered by single-phase VFDs. By adjusting the motor speed to match the load requirements, the VFD reduces energy wastage and improves overall energy efficiency. When the motor operates at a lower speed during periods of low demand, energy consumption is significantly reduced, resulting in energy savings and lower operating costs.
Motor protection is another important aspect addressed by single-phase VFDs. They incorporate various protective features, including overload protection, short circuit detection, and thermal protection, which help safeguard the motor against damage due to excessive current, voltage fluctuations, or overheating. This ensures reliable motor operation, prolongs the motor's lifespan, and reduces the risk of unexpected failures.
Harmonic filtering is also a critical consideration in single-phase VFD applications. When single-phase VFDs operate, they can introduce harmonics into the power supply, which may cause issues such as voltage distortions and interference with other electrical equipment. To mitigate these problems, single-phase VFDs often incorporate harmonic filtering techniques to suppress harmonics and ensure a clean and stable power supply, maintaining power quality and preventing damage to connected equipment.
Control algorithms play a significant role in single-phase VFD operation. These algorithms allow for precise control and adjustment of motor speed, ensuring smooth acceleration, deceleration, and accurate speed regulation. Advanced control algorithms enable efficient motor operation and enhance overall system performance.
In summary, single-phase VFDs provide precise control and regulation of single-phase motors in residential and small-scale applications. With their energy efficiency, motor protection features, harmonic filtering capabilities, and advanced control algorithms, single-phase VFDs enhance motor performance, reduce energy consumption, and ensure reliable operation in various residential and small-scale applications.
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