Vプロセス鋳造生産ライン: 革新的なグリーン鋳造プロセス

Vプロセス鋳造生産ラインの概要

産業の波に乗って 4.0, Vプロセス鋳造 (真空密閉成形プロセス) 生産ラインは、環境保護特性と優れた品質により、現代の鋳造分野の新たなベンチマークになりつつあります. この技術革新は日本発, 独自の負圧成形原理により、従来の鋳造プロセスの常識を完全に覆しました。.

I プロセスの原則と主要な利点

Vプロセス鋳造の核心は真空物理成形技術. 化学結合剤に依存する従来の砂型鋳造とは異なります。, このプロセスは、特製のプラスチックフィルムを150〜180℃の高温でラミネートします。, 真空負圧により乾燥珪砂が緻密に形成されます。. この物理的結合方法は 3 つの画期的な利点をもたらします。:

(1)環境保護革命:

プロセス全体を通じて接着剤は追加されません, 揮発性物質の排出は、 90%

(2)品質の飛躍的向上:

鋳物の表面粗さはRa12.5-25μmに達します。, そして 2 グレードにより寸法精度が向上します

(3)コストの最適化:

鋳物砂の再利用率は 98%, エネルギー消費は次のように削減されます。 30-40%

Ⅱ. インテリジェントな生産ラインのアーキテクチャ

最新の V プロセス鋳造ワークショップはモジュール設計を採用しており、主に 6 つの機能ユニットで構成されています。:

フィルム処理システムには、インテリジェントな温度制御フィルム加熱装置が装備されています。, 赤外線センサーにより膜厚を正確に制御, with an error not exceeding ±0.05mm. The automatic cutting mechanism can be adaptively adjusted according to the size of the sandbox.

The three-dimensional vibration table is equipped with a multi-directional electromagnetic vibrator (with a frequency adjustable from 25 to 50Hz), and is combined with a vacuum negative pressure system (maintaining a vacuum degree of -0.045 に -0.06MPa) to ensure the uniform distribution of the sand mold’s compaction degree. The latest model has integrated AI vibration pattern recognition technology, which can automatically optimize vibration parameters.

The intelligent pouring unit adopts a tilting pouring machine driven by a servo motor, with the tilting Angle accuracy of the pouring ladle reaching 0.1°. Combined with a laser liquid level monitoring system, it achieves a pouring weight control of ±1%. Some production lines have introduced a visual recognition system, which can automatically identify the gate position.

The sand treatment circulation system consists of multi-layer vibrating screens (with a screening efficiency of ≥98%), pneumatic conveying pipelines and sand temperature regulation devices. The innovatively designed sand cooling tower can stably control the temperature of molding sand at 35±2℃, ensuring the stability of the process.

The quality inspection module integrates an X-ray real-time imaging system (with a resolution of ≤0.5mm), a spectrometer and a 3D scanner to form a closed-loop control of casting quality. The key parameter data is uploaded to the MES system in real time to achieve full-process traceability.

Ⅲ. Detailed Analysis of the Process Flow

The intelligent laminated EVA film is precisely heated on the digital temperature control platform. The mechanical hand spreads at a constant speed of 0.02m/s, and the vacuum adsorption device ensures that the film adheres to the model with zero gap. The new type of ceramic coating spraying robot can achieve coating control at the 5μm level.

The sand mold construction adopts the stepped negative pressure loading technology. The contour formation is ensured in the initial stage of a gentle pressure of -0.03MPa, and the strength of the sand mold is enhanced in the later stage of a high pressure of -0.06MPa. The thickness of the sand layer was detected online by gamma rays, with a fluctuation range of ≤2mm.

The six-axis robot with intelligent box combination vision guidance completes the sand mold assembly, equipped with a laser alignment system, and the box combination accuracy reaches ±0.1mm. The new electromagnetic locking device provides adjustable preload (5-20kN) to ensure zero box expansion during the pouring process.

The low-carbon casting based on digital twin technology’s casting simulation system can optimize the casting plan in advance. During actual pouring, the thermocouple array monitors the changes in the temperature field in real time and dynamically adjusts the pouring speed (adjustable from 0.5 to 5kg/s).

Ⅳ. Industry Applications and Trends

現在のところ, V-process casting has been successfully applied in multiple fields:

建設機械: The counterweight blocks of 30-ton excavators are integrally formed

Rail transit: High-speed train brake disc casting (Surface quality Ra6.3μm)

Artistic casting: Large bronze sculpture, thin-walled parts (minimum wall thickness 3mm)

The cutting-edge development focuses on three major directions:

Digital twin platform: Achieving self-optimization of process parameters

Nano-coating technology: The surface finish of castings is further improved by 50%

Carbon neutrality solution: The waste heat recovery system can reduce energy consumption by 15%

V. Economic Analysis:

Taking a casting production line with an annual output of 20,000 tons as an example

Payback period: 2.8 年 (40% shorter than traditional techniques)

Comprehensive finished product rate: 93.5%

Cost per ton of castings: Reduced by 1,200 元 (based on the current market price)

The evolution of V-process casting technology not only represents an upgrade in casting techniques but also serves as a model for the green transformation of the manufacturing industry. With the deep integration of intelligent control systems and new material technologies, this process is reshaping the value chain of the modern casting industry. So it provides cleaner and more precise solutions for high-end equipment manufacturing. Its development trajectory confirms the innovation law of advanced manufacturing technology that “begins with substitution and ends with transcendence”, providing a transformation paradigm that can be referred to for the upgrading of traditional industries.

サプライヤー

洛陽豊洋重工業株式会社, 株式会社,1998年に設立された鉄道鋳造部品のメーカーです。当社の工場面積は72,600㎡です。, 以上の 300 従業員, 32 技術者, 含む 5 シニアエンジニア, 11 アシスタントエンジニア, そして 16 当社の生産能力は 30,000 年間トン. 現在, 私たちは主に鋳物を生産しています, 機械加工, 機関車の組立て,鉄道車両,高速鉄道, 鉱山機械,風力,etc.当社の製品はロシアに輸出されています, 米国, ドイツ, アルゼンチン, 日本, フランス, 南アフリカ,イタリアとその他の国.
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