阅读说明：本技术 一种智能化消失模白模发泡成型装置及其发泡方法 (Intelligent lost foam white mold foaming forming device and foaming method thereof ) 是由 孙爱民 曹刘洋 张颢 施懋祥 迟斌云 张超 于 2020-12-30 设计创作，主要内容包括：本发明公开了一种智能化消失模白模发泡成型装置及其发泡方法,属于模具生产技术领域。该装置包括：预发泡单元、熟化处理单元和发泡成型单元,所述熟化处理单元包括机架、熟化仓、气罐、进料管以及出料管,所述熟化仓置于机架上并列多个设置,进料管一端连接预发泡单元,另一端伸入熟化仓内；所述熟化仓的下端设置带阀门的出料口与所述气罐相连接,出料管一端连接在气罐的中下部,另一端连接至发泡成型单元。在熟化仓的下方设置一个气罐,通过气罐对珠粒实现快速输送,提高了发泡珠粒的输送速度,减少珠粒与空气接触吸收水分的可能性,珠粒的水分控制在1％以下,很好地满足发泡成型的条件。(The invention discloses an intelligent lost foam white mold foaming forming device and a foaming method thereof, and belongs to the technical field of mold production. The device includes: the curing device comprises a pre-foaming unit, a curing processing unit and a foaming and molding unit, wherein the curing processing unit comprises a rack, curing bins, a gas tank, a feeding pipe and a discharging pipe, the curing bins are arranged on the rack in parallel, one end of the feeding pipe is connected with the pre-foaming unit, and the other end of the feeding pipe extends into the curing bins; the lower extreme in curing storehouse sets up the discharge gate of taking the valve with the gas pitcher is connected, and discharging pipe one end is connected in the lower part of gas pitcher, and the other end is connected to the foaming shaping unit. An air tank is arranged below the curing bin, the beads are quickly conveyed by the air tank, the conveying speed of the foaming beads is improved, the possibility that the beads are contacted with air to absorb moisture is reduced, the moisture of the beads is controlled to be below 1%, and the foaming molding condition is well met.)

1. The utility model provides an intelligent disappearance mould white mould foaming forming device, includes:

a pre-foaming unit (100) for mixing the original beads with a foaming agent accounting for 4.8-7% of the mass fraction of the expanded beads, pre-foaming the mixture, and conveying the pre-foamed beads to the subsequent process;

a curing unit (200) for storing the pre-expanded beads so that the cells of the beads have enough time to permeate air and the foaming agent is uniformly diffused again;

a foaming molding unit (300) for filling the pre-foamed loose beads into a mold (320) having a certain shape and size, and heating again for secondary foaming to form an integral white mold having a shape and size identical to those of the mold (320);

the device is characterized in that the curing treatment unit (200) comprises a rack (210), curing bins (220), a gas tank (230), a feed pipe (240) and a discharge pipe (250), wherein the curing bins (220) are arranged on the rack (210) in parallel, one end of the feed pipe (240) is connected with the pre-foaming unit (100), and the other end of the feed pipe extends into the curing bins (220); the lower end of the curing bin (220) is provided with a discharge hole with a valve, the discharge hole is connected with the gas tank (230), one end of the discharge pipe (250) is connected to the middle lower part of the gas tank (230), and the other end of the discharge pipe is connected to the foaming forming unit (300).

2. The intelligent evaporative pattern white mold foaming device as claimed in claim 1, wherein the gas tank (230) comprises a cylindrical tank body (231), a conical cap (232) with a downward opening is arranged at the middle lower part of the inner side of the tank body (231), and a through hole is formed in the conical cap (232) to be connected with the discharge pipe (250).

3. The intelligent evaporative pattern white mold foaming device as claimed in claim 2, wherein a moisture measuring mechanism is arranged inside the conical cap (232), the moisture measuring mechanism comprises a near infrared moisture meter (234) and a mounting box (233), the mounting box (233) is fixed to the inside of the conical cap (232), the near infrared moisture meter (234) is arranged inside the mounting box (233), and the head of the near infrared moisture meter is vertically downward.

4. The intelligent lost foam white mold foaming device as claimed in claim 3, wherein the conical cap (232) is made of stainless steel.

5. The intelligent evaporative pattern white foam molding apparatus according to claim 4, wherein the mounting case (233) is provided with a transparent glass cover (235).

6. The intelligent evaporative pattern white mold foaming device as claimed in claim 4, wherein the cross-sectional shape of the conical cap (232) is trapezoidal, and the height thereof is 1/5-1/6 of the height of the tank (231).

7. The intelligent evaporative pattern white mold foam molding apparatus according to claim 1, wherein the pre-foaming unit (100) comprises a pre-foaming machine (110), a delivery pump (120) and a delivery pipe (130), the delivery pump (120) is connected to the delivery pipe (130), one end of the delivery pipe (130) is connected to the pre-foaming machine (110), and the other end is connected to the feeding pipe (240).

8. The intelligent evaporative pattern white mold foam molding device as claimed in claim 7, wherein the foam molding unit (300) comprises a foam molding machine (310) and a mold (320), the foam molding machine (310) comprises a base (311), a guide rod (312) and a pressure head (313), the mold (320) is arranged on the base (311), the pressure head (313) is arranged opposite to the base (311), the pressure head (313) moves up and down along the guide rod (312), a heating element is arranged in the pressure head (313), and the discharge pipe (250) is connected to a feed inlet of the pressure head (313).

9. The intelligent evaporative pattern white mold foaming device as claimed in claim 1, further comprising a water supply unit, wherein the water supply unit comprises a water pump and a water inlet pipe, and the water inlet pipe is connected with the pressure head (313).

10. The intelligent evaporative pattern white mold foaming device as claimed in claim 8, wherein the mold (320) is made of aluminum alloy.

11. The foaming method of the intelligent evaporative pattern white mold foaming device as claimed in claims 1 to 10, characterized by comprising the following specific steps:

step S101, mixing the selected original beads with a foaming agent accounting for 4.8-7% of the mass fraction of the expanded beads, and then pre-foaming in a pre-foaming machine (110), wherein the pre-foaming machine (110) is used for pre-foamingThe steam pressure is controlled at 0.1-0.2Mpa, the expansion chamber pressure is controlled at 0.03-0.06Mpa, the temperature is 90-100 deg.C, the time is 40-60 s, and the density of the original beads after foaming is controlled at 0.018-0.025g/cm³The foaming times are 30-40 times;

s102, conveying the pre-foamed beads to a curing bin (220) of a curing treatment unit (200), placing for 12-24h, then putting into a gas tank (230), and transferring to a foaming forming machine (310) of a foaming forming unit (300) from the gas tank (230);

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, pre-mold lifting, demolding and mold stripping of the foaming forming machine (310) to finish the manufacturing of the lost foam white mold.

12. The foaming method of the intelligent evaporative pattern white mold foaming device as claimed in claim 11, wherein the original beads are EPS, STMMA or EPMMA.

13. The foaming method of an intelligent evaporative pattern white mold foaming device as claimed in claim 12, wherein the primary beads have a particle size range of 0.25-0.85 mm.

14. The foaming method of an intelligent evaporative pattern white mold foaming device according to claim 13, wherein the foaming unit (300) comprises at least two foaming molding machines (310), the number of tasks is set for each foaming molding machine (310), and then the number of completed foaming molding machines (310) is compared, and when the number of completed tasks is equal to the number of tasks, the corresponding foaming molding machine (310) cannot be put into operation.

15. The foaming method of the intelligent evaporative pattern white mold foaming device according to claim 14, wherein the mold (320) of each foaming machine (310) is scanned and the codes of the scanned molds (320) are compared, and when the scanned molds (320) are not producing products, the foaming machines (310) cannot be put into operation.

Technical Field

The invention relates to the technical field of mold production, in particular to an intelligent lost foam white mold foaming and forming device and a foaming method thereof.

Background

The lost foam casting is a novel casting method which comprises the steps of bonding and combining paraffin or foam models with similar sizes and shapes to form a model cluster, coating refractory paint, drying, burying in dry quartz sand for vibration modeling, pouring under negative pressure to enable the model to be gasified, enabling liquid metal to occupy the position of the model, solidifying and cooling to form the casting. The lost foam casting is a new process with near allowance-free and accurate molding, and the process does not need to take a mold, a parting surface or a sand core, so that the casting does not have flash, burrs or draft inclination, and the size error caused by the combination of the core is reduced. The roughness of the surface of the casting can reach Ra3.2-12.5 mu m; the size precision of the casting can reach CT 7-9; the machining allowance is 1.5-2 mm at most, the machining cost can be greatly reduced, and compared with the traditional sand casting method, the machining time can be reduced by 40-50%. At present, a wear-resistant casting is produced by a lost foam casting method in China by a plurality of enterprises, and good effects are achieved: for example, Wuhan Henchang special steel casting factory produces wear-resistant alloy cast steel helical stirring blades, a squirrel cage crusher rotor and an arc-shaped wear-resistant sieve plate, Wuxi Yonxin full-mold casting company Limited produces high-chromium cast iron wear-resistant helical blades, a blast furnace wall lining plate and a wear-resistant grinding disc, Negmeng Chifeng Futz technical service company Limited produces wear-resistant alloy pear thorn plates, Wuxi Zhifu lost foam casting studio produces a chromium-nickel alloy brick making machine high-chromium reamer and a wear-resistant heat-resistant combined tapered grid plate, Beijing Tiantaimen lost foam casting company produces bulldozer shovel teeth and tooth sleeves, Sichuan Panzhihua mining industry company produces excavator super-large shovel teeth and mining down-the-hole drill creeper plate, and Xiangtan lake foot mechanical factory produces tank-Jiang creeper plate.

Therefore, the lost foam casting is widely popularized, wherein a lost foam white mold (also called a lost foam pattern) is used as a core component for casting, the using amount is large, and the large-scale production is required to meet the using requirement.

The foaming forming process of the lost foam white mold is nearly mature at present, for example, a patent application document with the Chinese patent application number of 201210124625X and the publication date of 2013, 10 and 30 discloses a lost foam production process of an automobile engine cylinder body, which comprises the step S1 of pre-foaming process of beads; s2, the white mold forming process; s3, drying the white mould according to the drying treatment process; s4, carrying out the die bonding process; s5, dip-coating the coating; s6, drying after dip coating; s7, the molding and casting process. Chinese patent application No. 2017107795643, published as 2018, 2 and 23, discloses a steam pre-foaming process for lost foam beads, which comprises the following steps: s1, preheating, which comprises the following two steps: s11, preheating the entering steam; s12, preheating of steam inlet and outlet circulation: preheating by steam to make the temperature in the pre-foaming barrel reach 90-95 ℃, and circularly preheating by discharging the steam to make the temperature in the pre-foaming barrel stable; s2, adding materials: introducing the original beads into a pre-foaming machine bin, and adding a trace amount of zinc stearate into the original beads to be pre-foamed; heating and foaming: the pressure of the steam pipeline is 0.3-0.4Mpa, and the pipeline steam pressure of the pre-expander must be stably controlled at 0.1-0.2 Mpa; the pressure of the expansion chamber is controlled to be 0.03-0.06Mpa, the temperature is 90-105 ℃, and the time is 30-70 s; s3, drying: the pre-expanded beads were placed in a fluidized bed and dried. The patent application with Chinese patent application number 2010105870949 and publication date 2015, 4 and 8 discloses a manufacturing method of an automobile beam lost foam, which comprises the following steps: a. selecting proper STMMA beads, and detecting the moisture and volatile matters of the beads; b. pre-foaming: the intermittent steam pre-expander firstly passes through a steam-water separation device to fully remove redundant water in the intermittent steam pre-expander, and then sends the STMMA beads into the intermittent steam pre-expander; c. curing: the curing control time of the spherulites is 12 to 48 hours; d. filling the cured beads into a lost foam mold, and cooling and forming to obtain a lost foam I and a lost foam II; e. entering a drying room; f. and inserting and connecting the first evaporative pattern and the second evaporative pattern together to form the automobile beam evaporative pattern. The patent application with Chinese patent application number 2014107000568 and publication date 2015, 4 and 8 discloses a preparation process of a lost foam casting pattern, which comprises the following steps: 1) pre-foaming the steam by using an air compressor, and pre-foaming the raw materials; 2) placing the pre-expanded beads in a dry and ventilated bin for curing; 3) producing a foam pattern or a gating system using a metal foaming mold; in the first step, the raw material is EPS, EPMMA or STMMA plastic film.

In addition, some journal papers disclose related foaming molding equipment and processes, for example, "lost foam white mold foaming molding equipment and mold" (ltsan et al, research on casting equipment, 12 months 2007) disclose equipment and operation processes of foaming raw materials, molding mold, white mold bonding (cluster, pouring system), drying, coating, and the like. Key control of working procedure of lost foam casting white mould area of iron casting (gaoyang, casting process, 5 th 2020), discloses several key areas in working procedure of lost foam casting white mould area, according to principle of process quality control, the quality control scheme of the working procedures of bead model selection, prefoaming, drying/curing, forming foaming, bonding combination and the like of the lost foam casting white mould area of iron casting is discussed and analyzed, and key process parameters and control key points thereof are provided. The research on the production of lost foam white molds (Bai Yu Branch, science and technology Innovation, 2011, NO25) discloses the material of the mold sample and the manufacturing process of the mold sample.

From the above information, the foam molding process of the lost foam white mold mainly includes three steps: pre-foaming, curing and foaming molding, wherein curing is carried out by putting pre-foamed foam beads into a curing bin, and during the curing process of the beads, most of water is naturally lost, certain elasticity is recovered, and the content of volatile matters is reduced; if the pre-foaming is not good, the surface of the foam is foamed, some foam is elliptical, the elasticity is not good, and volatile matters are volatilized relatively quickly, so that the foam forming is not facilitated. Therefore, the technical scheme disclosed by the patent technology or the paper journal has less description on the curing process; furthermore, the cured beads need to be transferred to a foam forming machine, in which process as little air contact as possible is required to reduce the moisture absorption of the beads (too high moisture directly affects foam forming, generally moisture < 1%), but the speed of transfer is also critical in addition to pipe transfer.

Disclosure of Invention

1. Problems to be solved

Aiming at the limitation of the existing lost foam white mold production equipment and the problem of water absorption caused by the fact that rapid conveying of expanded beads cannot be achieved, the invention provides the intelligent lost foam white mold foaming and forming device and the intelligent lost foam white mold foaming and forming method, which are used for improving the conveying speed of the expanded beads, reducing the possibility that the beads are contacted with air to absorb water and meeting the foaming and forming conditions.

2. Technical scheme

In order to solve the problems, the technical scheme adopted by the invention is as follows:

the invention discloses an intelligent lost foam white mold foaming forming device, which comprises:

the pre-foaming unit is used for mixing the original beads with a foaming agent accounting for 4.8-7% of the mass fraction of the expanded beads, pre-foaming the mixture, and conveying the pre-foamed beads to the subsequent process;

the curing treatment unit is used for storing the pre-expanded beads, so that the air can be permeated into the pores of the beads in enough time, and the foaming agent can be uniformly diffused again;

a foaming forming unit, filling the pre-foamed loose beads into a mould with a certain shape and size, heating again for secondary foaming to form an integral white mould with the shape and size consistent with the mould;

the curing treatment unit comprises a rack, curing bins, a gas tank, a feed pipe and a discharge pipe, the curing bins are arranged on the rack in parallel, one end of the feed pipe is connected with the pre-foaming unit, and the other end of the feed pipe extends into the curing bins; the lower extreme in curing storehouse sets up the discharge gate of taking the valve with the gas pitcher is connected, and discharging pipe one end is connected in the lower part of gas pitcher, and the other end is connected to the foaming shaping unit.

In a possible embodiment of the invention, the gas tank comprises a cylindrical tank body, a conical cap with a downward opening is arranged at the middle lower part of the inner side of the tank body, and a through hole is formed in the conical cap and connected with the discharge pipe.

In a possible implementation manner of the present invention, a moisture measuring mechanism is disposed on an inner side of the conical cap, the moisture measuring mechanism includes a near-infrared moisture meter and a mounting box, the mounting box is fixed to the inner side of the conical cap, the near-infrared moisture meter is disposed in the mounting box, and a head of the near-infrared moisture meter faces downward vertically. By adopting the device, the water content can be measured on line in real time, the adjustment is carried out immediately, the rationality of feedback control parameters is realized, the field control tends to be straight and white, the intelligent production line is convenient to construct, and the water content of the beads is controlled to be 0.5-1.0%.

In a possible embodiment of the invention, the conical cap is made of stainless steel.

In a possible embodiment of the invention, the mounting box is provided with a transparent glass casing.

In one possible embodiment of the present invention, the cross-sectional shape of the conical cap is a trapezoid, and the height of the conical cap is 1/5-1/6 of the height of the can body.

In one possible embodiment of the present invention, the pre-foaming unit includes a pre-foaming machine, a delivery pump and a delivery pipe, the delivery pump is connected to the delivery pipe, one end of the delivery pipe is connected to the pre-foaming machine, and the other end of the delivery pipe is connected to the feeding pipe.

In a possible embodiment of the present invention, the foam molding unit includes a foam molding machine and a mold, the foam molding machine includes a base, a guide rod and a pressing head, the mold is disposed on the base, the pressing head and the base are disposed opposite to each other, the pressing head moves up and down along the guide rod, a heating element is disposed in the pressing head, and the discharge pipe is connected to a feed inlet of the pressing head.

In a possible embodiment of the present invention, the present invention further comprises a water supply unit, wherein the water supply unit comprises a water pump and a water inlet pipe, and the water inlet pipe is connected to the pressure head. When water spray cooling is employed, a plurality of nozzles may be provided in the mold wall of the air chamber of the base to increase the cooling rate.

In one possible embodiment of the invention, the die is made of aluminum alloy (forged aluminum or cast aluminum), so that the die is light in weight, good in heat conductivity and good in processability, and can achieve the purpose of accurate and stable die shape and size.

The invention also provides a foaming method of the intelligent lost foam white mold foaming and forming device, which comprises the following specific steps of:

step S101, mixing the selected original beads with a foaming agent accounting for 4.8-7% of the mass fraction of the expanded beads, and then pre-foaming in a pre-foaming machine, wherein steam of the pre-foaming machineControlling pressure at 0.1-0.2Mpa, pressure in expansion chamber at 0.03-0.06Mpa, temperature at 90-100 deg.C, time at 40-60 s, and density of original beads after foaming at 0.018-0.025g/cm³The foaming times are 30-40 times;

s102, conveying the pre-foamed beads to a curing bin of a curing treatment unit, standing for 12-24h, then putting into a gas tank, and transferring to a foaming forming machine of a foaming forming unit from the gas tank;

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, mold pre-lifting, demolding and demolding of the foaming molding machine, and finishing the manufacturing of the lost foam white mold.

In one possible embodiment of the invention, the primary beads are EPS, STMMA or EPMMA.

In one possible embodiment of the invention, the primary beads have a particle size in the range of 0.25 to 0.85 mm.

In a possible embodiment of the present invention, the foam molding unit includes at least two foam molding machines, the number of tasks is set for each foam molding machine, and the number of completed foam molding machines is compared, and when the number of completed foam molding machines is equal to the number of tasks, the corresponding foam molding machine cannot be put into operation.

In a possible embodiment of the present invention, the mold of each foam molding machine is scanned and the scanned mold codes are compared, and when the scanned mold is not a product, the foam molding machine cannot be put into operation.

3. Advantageous effects

Compared with the prior art, the invention has the beneficial effects that:

(1) according to the intelligent lost foam white mold foaming forming device, the air tank is arranged below the curing bin, beads are quickly conveyed through the air tank, the conveying speed of the foaming beads is improved, the possibility that the beads are contacted with air to absorb moisture is reduced, the moisture of the beads is controlled to be below 1%, and the foaming forming conditions are well met;

(2) according to the intelligent lost foam white mold foaming forming device, the beads falling from the curing bin can fall into the bottom of the gas tank, and a local negative pressure area can be formed on the lower side of the conical cap through the design of the conical cap, so that the discharge of the beads can be accelerated;

(3) the intelligent lost foam white mold foaming forming device can measure the water content in real time on line, adjust the water content in real time, feed back the rationality of control parameters, and control the water content of beads to be 0.5-1.0 percent, wherein the on-site control tends to be straight whitening, so that the intelligent production line is convenient to construct; when the moisture is too high, the air tank can be heated, hot air is introduced, and the like to reduce the moisture of the beads;

(4) the intelligent lost foam white mold foaming forming device is simple in structure and easy to manufacture.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.

Fig. 1 is a schematic perspective view of an intelligent evaporative pattern white mold foaming device according to the present invention;

fig. 2 is a schematic front view of the intelligent evaporative pattern white mold foaming device according to the present invention;

FIG. 3 is a schematic view of the gas tank structure of the intelligent evaporative pattern white mold foaming device of the invention;

fig. 4 is a cross-sectional view taken along line a-a of fig. 3.

The notation in the figure is:

100. a pre-foaming unit; 110. pre-foaming machine; 120. a delivery pump; 130. a delivery pipe;

200. a curing treatment unit; 210. a frame; 220. a curing bin; 230. a gas tank; 231. a tank body; 232. a conical cap; 233. mounting a box; 234. a near infrared moisture meter; 235. a transparent glass housing; 240. a feed pipe; 250. a discharge pipe;

300. a foam molding unit; 310. a foaming forming machine; 311. a base; 312. a guide bar; 313. a pressure head; 320. and (5) molding.

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

For a further understanding of the invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings and examples.

Example 1

As shown in fig. 1 to 4, the intelligent evaporative pattern white mold foaming device of the present embodiment includes: a pre-foaming unit 100 for pre-foaming the mixture of the original beads and a foaming agent in an amount of 4.8 to 7% by mass of the expanded beads, and transferring the pre-foamed beads to a subsequent process; a curing unit 200 for storing the pre-expanded beads so that the pores of the beads have enough time to permeate air and the foaming agent is uniformly diffused again; the foaming and molding unit 300 fills the pre-foamed loose beads in a mold 320 having a certain shape and size, and heats again to perform secondary foaming to form an integral white mold having a shape and size identical to those of the mold 320.

The content of the foaming agent in the original beads is generally 4.8-7%, and if the content of the foaming agent is higher than 7%, in order to prevent the foam from cracking and changing caused by surface overfoaming, the original beads need to be exposed in the air for a period of time before foaming, and foaming is carried out after the content of the foaming agent meets the requirement; if the blowing agent content is below the requirement, it is controlled by adjusting the pressure and time parameters during the pre-foaming process.

It should be noted that a certain amount of foaming agent is retained in the beads immediately after pre-foaming, and particularly, the beads pre-foamed by steam are accompanied by partial steam, and when the beads are taken out of the machine, the beads are condensed into liquid foaming agent and are melted into polystyrene again, so that the pressure of bubbles is reduced, negative pressure is generated, the beads are easy to deform, and the beads cannot be immediately used in the molding and foaming process. To avoid this, the pre-expanded beads must be dried and cured. On the basis, the curing treatment unit 200 comprises a rack 210, a curing bin 220, a gas tank 230, a feed pipe 240 and a discharge pipe 250, wherein the curing bin 220 is arranged on the rack 210 in parallel, one end of the feed pipe 240 is connected with the pre-foaming unit 100, and the other end of the feed pipe extends into the curing bin 220; the lower end of the curing bin 220 is provided with a discharge hole with a valve, the discharge hole is connected with the gas tank 230, one end of the discharge pipe 250 is connected to the middle lower part of the gas tank 230, and the other end is connected to the foaming and molding unit 300.

By introducing the pre-expanded beads into the gas tank 230, the inert gas may be introduced into the gas tank 230 or the gas tank 230 may be under negative pressure, thereby accelerating the rapid movement of the beads and reducing the process operation time.

Further, as shown in fig. 3 and 4, the gas tank 230 includes a cylindrical tank 231, a conical cap 232 made of stainless steel and having a downward opening is disposed at a middle lower portion of an inner side of the tank 231, and a through hole is formed in the conical cap 232 to be connected to the discharge pipe 250. The beads falling from the ripening bin 220 fall to the bottom of the gas tank 230, and a partial negative pressure area is formed on the lower side of the conical cap 232 through the design of the conical cap 232, so that the discharge of the beads can be accelerated.

Before the beads enter the foaming and forming machine 310, the monitoring of moisture is also important, and generally is not more than 1%, therefore, the inner side of the conical cap 232 is provided with a moisture measuring mechanism, the moisture measuring mechanism comprises a near infrared moisture meter 234 and a mounting box 233, the mounting box 233 is provided with a transparent glass cover 235, the beads can be prevented from entering the mounting box 233, the work of the near infrared moisture meter 234 can be avoided being influenced, the mounting box 233 is fixed with the inner side of the conical cap 232, the near infrared moisture meter 234 is arranged in the mounting box 233, and the head of the near infrared moisture meter 234 faces downwards vertically. By adopting the device, the water content can be measured on line in real time, the adjustment is carried out immediately, the rationality of feedback control parameters is realized, the field control tends to be straight and white, the intelligent production line is convenient to construct, and the water content of the beads is controlled to be 0.5-1.0%. When the moisture is too high, the air tank 230 may be subjected to a heating treatment, hot air may be introduced, or the like to reduce the moisture of the beads.

The working principle is as follows: the online near-infrared moisture meter 234 operates on the principle that water molecules absorb near-infrared light of certain wavelengths particularly strongly, the water molecules have characteristic absorption peaks in the near-infrared light region, the water molecules absorb near-infrared light strongly, and if the substance to be measured is irradiated with the near-infrared light of the two wavelengths, the moisture of the substance can be measured by measuring the attenuation degree of transmitted light or reflected light. The water molecules have strong absorption to 1940nm, 1450nm, 1190nm, 970nm and 760 nm. In the near infrared absorption peak of water, the absorption rate at the wavelength of 1190nm is small, and the method is generally used for measuring the humidity of more than 50 percent; the absorption rate at the wavelength of 2950nm is too large, the humidity measurement range is narrow, and the method is generally used for measuring in a small range and with high precision; the absorption rate of 1450nm and 1940nm wavelength is proper, and the method can be used for humidity measurement in the industrial field. It is through extensive experimentation and research that the inventors have analyzed the performance of the near infrared moisture meter 234 and the beads, selecting reference light and measuring light having a wavelength of 1940 nm. The light intensity and water content calculation data of the near infrared moisture meter 234 are shown in table 1.

Table 1 light intensity and moisture content calculation data for near infrared moisture meter 234

In addition, the cross-sectional shape of the conical cap 232 is trapezoidal, and the height thereof is 1/5-1/6, preferably 1/5, of the height of the can 231.

In this embodiment, the pre-foaming unit 100 includes a pre-foaming machine 110, a delivery pump 120 and a delivery pipe 130, the delivery pump 120 is connected to the delivery pipe 130, one end of the delivery pipe 130 is connected to the pre-foaming machine 110, and the other end is connected to the feeding pipe 240.

In this embodiment, the foam molding unit 300 includes a foam molding machine 310 and a mold 320, the foam molding machine 310 includes a base 311, a guide rod 312 and a ram 313, the mold 320 is disposed on the base 311, the ram 313 is disposed opposite to the base 311, the ram 313 moves up and down along the guide rod 312, a heating element is disposed in the ram 313, and the discharge pipe 250 is connected to a feed inlet of the ram 313.

In this embodiment, the water supply device further comprises a water supply unit, wherein the water supply unit comprises a water pump and a water inlet pipe, and the water inlet pipe is connected with the pressure head 313. When water spray cooling is adopted, a plurality of nozzles can be arranged on the mold wall of the air chamber on the base, so that the cooling speed is improved.

In this embodiment, the mold 320 is made of aluminum alloy (forged aluminum or cast aluminum), which has light weight, good thermal conductivity and good processability, and can achieve accurate and stable shape and size of the mold 320.

The foaming method of the intelligent lost foam white mold foaming and forming device comprises the following specific steps:

step S101, mixing the selected original beads with a foaming agent accounting for 4.8% of the mass fraction of the expanded beads, and then pre-foaming in a pre-foaming machine 110, wherein the steam pressure of the pre-foaming machine 110 is controlled to be 0.1MPa, the pressure of an expansion chamber is controlled to be 0.03MPa, the temperature is 90 ℃, the time is 40 seconds, and the density of the original beads after foaming is controlled to be 0.018g/cm³The foaming multiple is 30 times;

step S102, conveying the pre-expanded beads to a curing bin 220 of a curing treatment unit 200, standing for 12 hours, then putting the beads into a gas tank 230, and transferring the beads from the gas tank 230 to a foaming forming machine 310 of a foaming forming unit 300;

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, mold pre-lifting, demolding and mold stripping of the foaming forming machine 310, and finishing the manufacturing of the lost foam white mold. The parameters of pre-blowing, material punching, preheating, main heating, water cooling, pre-mold lifting, mold stripping and mold stripping of the foam molding machine 310 are disclosed in the prior art, such as patent application No. 2010105870949.

Further, the foam molding unit includes at least two foam molding machines 310 (the foam molding machines 310 are electrically connected to the PLC controller), the number of tasks is set for each foam molding machine 310, the number of completed foam molding machines 310 is compared, and when the number of completed foam molding machines is equal to the number of tasks, the corresponding foam molding machines 310 cannot be put into operation.

In this embodiment, each mold is provided with a barcode, the barcode includes related mold information, the mold 320 of each foam molding machine 310 is scanned (the foam molding machine 310 is matched with a barcode scanner, and the barcode scanner is electrically connected to the PLC controller), and the scanned mold 320 codes are compared (related comparison technology is disclosed, for example, in patent 200910300731.7), when the scanned mold 320 is not a product, the foam molding machine 310 cannot be put into a working state, and an alarm is issued.

In this example, the primary bead particle size ranges from 0.25 to 0.85 mm; the original beads are EPS, STMMA or EPMMA. (1) EPS (polystyrene), translucent particles, w (C)92 percent, has minimum gas evolution, and is generally suitable for nonferrous metals (Al, Cu and the like), gray cast iron and general steel castings; (2) STMMA (copolymer resin), opalescent semitransparent particles w (C) 60-90%, and the gas forming amount is low, so that the high-performance liquid steel is generally suitable for gray cast iron, nodular cast iron low-carbon steel, alloy steel and the like; (3) EPMMA (polymethyl methacrylate), translucent particles, w (C) 60%, has the largest gas evolution, and is generally suitable for nodular cast iron, malleable cast iron, low-carbon steel, alloy steel and the like.

Example 2

The foaming method of the intelligent lost foam white mold foaming and forming device comprises the following specific steps:

step S101, mixing the selected original beads with a foaming agent accounting for 7% of the mass fraction of the foamed beads, and then pre-foaming in a pre-foaming machine 110, wherein the steam pressure of the pre-foaming machine 110 is controlled at 0.2MPa, the pressure of an expansion chamber is controlled at 0.03MPa, the temperature is 95 ℃, the time is 60 seconds, and the density of the original beads after foaming is controlled at 0.025g/cm³The foaming ratio is 40 times;

s102, conveying the pre-foamed beads to a curing bin 220 of a curing treatment unit 200, standing for 12-24h, then putting the beads into a gas tank 230, and transferring the beads from the gas tank 230 to a foaming forming machine 310 of a foaming forming unit 300;

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, mold pre-lifting, demolding and mold stripping of the foaming forming machine 310, and finishing the manufacturing of the lost foam white mold.

Example 3

The foaming method of the intelligent lost foam white mold foaming and forming device comprises the following specific steps:

step S101, mixing the selected original beads with a foaming agent accounting for 5.2% of the mass fraction of the expanded beads, and then pre-foaming in a pre-foaming machine 110, wherein the steam pressure of the pre-foaming machine 110 is controlled to be 0.15MPa, the pressure of an expansion chamber is controlled to be 0.05MPa, the temperature is 100 ℃, the time is 50 seconds, and the density of the original beads after foaming is controlled to be 0.020g/cm³The foaming multiple is 35 times;

s102, conveying the pre-foamed beads to a curing bin 220 of a curing treatment unit 200, standing for 12-24h, then putting the beads into a gas tank 230, and transferring the beads from the gas tank 230 to a foaming forming machine 310 of a foaming forming unit 300;

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, mold pre-lifting, demolding and mold stripping of the foaming forming machine 310, and finishing the manufacturing of the lost foam white mold.

Example 4

The foaming method of the intelligent lost foam white mold foaming and forming device comprises the following specific steps:

step S101, mixing the selected original beads with a foaming agent accounting for 6.5 percent of the mass fraction of the expanded beads, and then pre-foaming in a pre-foaming machine 110, wherein the steam pressure of the pre-foaming machine 110 is controlled to be 0.18MPa, the pressure of an expansion chamber is controlled to be 0.05MPa, the temperature is 90 ℃, the time is 40 seconds, and the density of the original beads after foaming is controlled to be 0.018g/cm³The foaming ratio is 40 times;

s102, conveying the pre-foamed beads to a curing bin 220 of a curing treatment unit 200, standing for 12-24h, then putting the beads into a gas tank 230, and transferring the beads from the gas tank 230 to a foaming forming machine 310 of a foaming forming unit 300;

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, mold pre-lifting, demolding and mold stripping of the foaming forming machine 310, and finishing the manufacturing of the lost foam white mold.

Example 5

The foaming method of the intelligent lost foam white mold foaming and forming device comprises the following specific steps:

step S101, mixing the selected original beads with a foaming agent accounting for 6.0% of the mass fraction of the foamed beads, and then pre-foaming in a pre-foaming machine 110, wherein the steam pressure of the pre-foaming machine 110 is controlled to be 0.1MPa, the pressure of an expansion chamber is controlled to be 0.03MPa, the temperature is 100 ℃, the time is 60 seconds, and the density of the original beads after foaming is controlled to be 0.025g/cm³The foaming multiple is 30 times;

s102, conveying the pre-foamed beads to a curing bin 220 of a curing treatment unit 200, standing for 12-24h, then putting the beads into a gas tank 230, and transferring the beads from the gas tank 230 to a foaming forming machine 310 of a foaming forming unit 300;

and S103, setting parameters of pre-blowing, material punching, preheating, main heating, water cooling, mold pre-lifting, demolding and mold stripping of the foaming forming machine 310, and finishing the manufacturing of the lost foam white mold.

The above description is a more detailed description of the present invention with reference to specific preferred embodiments, and it is not intended to limit the present invention to the specific embodiments described above. It will be apparent to those skilled in the art that various modifications, additions, substitutions, and the like can be made without departing from the spirit of the invention.