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1、ConfiguringcastingproductionequipmentandplantlayoutDieCastingisasmall,nocuttingofnearnetshapemetalhotforming,castinglighthavingaquality,cleancut,sizezprecisionandconsistencyandinterchangeabilitycharacteristics,andjustafterasmallamountofmachiningorevenhavingtoprocess,youcandirectlyusetheassembly.Also
2、,therearedie-castingproductionprocessenergysaving,highefficiency,lowconsumption,andmanyotheradvantages,whicharewidelyusedinmanyfieldsofautomobile,motorcycle,householdappliances,instruments,aerospace,electronics,weapons,hardware,lighting,etc.,plusanotherlureatthehigh-efficiencyandhighrateofreturnisdr
3、ivengreatlyattractedmanyinvestors,mostpeopletakeascientificattitude,steadypace,positiveprogress,success.Nowdie-castingindustrythrivingenoughtoexplainitsstrongmomentum.Castingproductionplantandequipmentshouldmeettheprofessionalrequirements,itsassociatedresourcesandmaterialssurroundingthedie-castingpr
4、ofessionalneedsshouldbeconfigured.Tothisend,theformationofdie-castingbusinessshouldknowsomethingaboutandawarenessinordertodeterminethetypeofequipment,specifications,projects,andaccordingtothenumberofprimaryinvestmentscale,andtoselecttheappropriateequipmenttoconsiderplantlayout.First,thedie-castingpr
5、oductionequipmentconfigurationDie-castingproductionequipmentshouldbeconfiguredmore,thefollowingwereoutlined.1. BasicequipmentThebasicequipmentincludes:diecastingmachine,meltingfurnaceandholdingfurnace.Diecastingmachineiscastingproductionofthemainequipment,clampingforce4000KNminicomputer,4000-10000KN
6、mainframe.Diecastingmachinesizeandtypecanbedeterminedbytheselectionofdie-castingwork.Themoltenmetalisgoodholdingfurnacewasmaintainedatatemperaturerangeofprocessequipmentneeds,usuallyplacedatthesideofthediecastingmachine.Whenthesmallscaleofproduction(suchasdie-castingmachineonly1-2units)inthecase,but
7、alsoasamoltenmetalholdingfurnaceuse,temporarilywithanothermeltingfurnace,butthisapproachisonlyanexpedientmeasurequality,liquidmetalwillbeinfluences.Meltingfurnaceisdedicatedtothemoltenmetalingotmaterialormaterialsoundequipment,thefurnacecapacityshouldbeadequate,deliveryofmoltenmetaltoacertainnumbero
8、fholdingfurnace.Whenconfiguringthemeltingfurnaceofmoltenmetalqualityismoreguaranteed.2. AuxiliaryEquipmentAuxiliaryequipmentformechanizedorautomatedhostandequipped.Assistingdevicecomprising:meanstoppings,spraying(includingcleaningmeansandthepick-updeviceisequippedwithauxiliarydevicesnotonlyinorderto
9、reducetheamountoflabor,improvelaborefficiency,increaseeconomicefficiency,butalsoforcastingqualitycertificationisparticularlyimportant.).(1)meanstoppingsjustcoldchamberdiecastingmachineconfiguration,withthisarrangement,themoltenmetalispouredintothepressurechambercanbequantifiedinfavorofthepositionofe
10、achsegmentofthetrippointofinjectionprocessisrelativelystable,cakethicknessmoreconsistent,whichiscoldchamberdiecastingmachineisveryimportant.Furnacehotchamberdiecastingmachineisplacedinthemachine,donotre-provisiontoppingsdevices.(2)Functionofthesprayingmeansis:theprocessofdie-castingoperation,intheca
11、seofopenmold,themoldpartingsurfacetocleanmetalanddebris,sprayingamoldreleaseagent,whilesprayingcompressedairtothemoldItcanplayacoolingeffect.(3) pick-upmeansforthedie-outofthecastingmoldisremovedfrombetweentheopenfile.(4) forsprayingortakepiecesofwork,butalsoconfiguretherobottocomplete.Withamorecomp
12、letesprayingrobotwithpicktwofunctions.Formechanizedorautomatedproductionmethods,theresponseofeachdiecastingmachineatthesametimecompletewithallthreedevices.Forgeneralmodeofproduction,donotconfigureasecondarydevice:canalsobeindividuallyconfiguredonlyoneortwo,then,accordingtotheimportanceoftheroleofthe
13、sedevices,accordingtothetoppings,painting,takingtotheconfigurationitemsinthisorder.3. PeripheralsInthediecastingmachineproductionline,peripheraldevicestypicallyinclude:trimmingmachine,adiecastingpartialinspectionapparatus,acastingmoldimmediatecoolingdevice,thereleaseagentfeedingdevice,insertmoldedin
14、tothepreheatingdeviceconfiguredinaccordancewithspecificitemsofequipmentcircumstances.Forthedie-castingunitisconfiguredprojectisIikelytobemore.4. AdditionalspecialdevicesWhentherearespecialtechniquesrequired,itshouldalsobeconfiguredvacuumapparatus,moldtemperaturecontroldevicesandlocalpressuredevices.
15、5. clearingequipmentClearingprocessisadie-castingproductionlineaftertheprocedure,anditsequipmentare:trimmingmachine,bandsawmachines,beltmachine,grindingmachine,sandblastingmachine,shotpeeningmachines,rollerdeburringmachinevibrationpolisher,etc.6. testinginstrumentsandequipmentCastingproductionwithte
16、stinginstrumentsandequipmentshouldbeinaccordancewiththespecificcircumstancesoftheaccuracyofproductparts,testitemsandcontentrequirements.Generallyfromtheprimary,simpletoadvanced,sophisticated,canechelonrespectively,canalsobeconfiguredwithachoiceofseveralmutual.Formanykindsofproducts,hightechnicalrequ
17、irements,theproductionoflarge-scaleenterprises,thentrytoconfigurewhole.Correlationdetectionequipmentasfollows:(1)measuringthelengthofconventionalmeasuringtools,micrometerzdialgauge,gauge,inclinometer,projectors,coordinateandspecialmeasuringtools.(2) artificialvisualappearanceofthesurface,flatnessdet
18、ector;roughnessdetector.(3) thechemicalcompositionoflaboratoryanalysisspectrometer.(4) themechanicalpropertiesofmaterialstestingmachines,hardnessandsoon.(5) internaldefectsmetallurgicaltestequipment,industrialX-raydetectionmachine,assayequipment,colortestequipment,ultrasonicflawdetectorscontrol,clos
19、edpressuretestequipment.(6) Forthetimebeingtherearenoconditionsorequipmentinstalledfortestingequipmentbusiness,cancountcommissionedinspectioncentertesting.7. TransportandliftingequipmentDie-castingproduction,transportwithintheplantmaterialmainlyreferstothemaintenancematerialmetalingots,moltenmetal,c
20、astingfinishedparts,scrappiecesofdie-casting,metal,cake,mold,processplantgateanddrainoverflowsystem,avarietyofdevicespartsandspareparts.Forthetransportofsuchmaterialsusuallydidnotpreparethetruck,carbatteries,drivinglifting.Whenatahigherdegreeofautomationorcomponentdie-castingunitcanbeconfiguredfordi
21、e-castingmetal,maybeusedconveyormeans.Asforthemethodfromthemeltingfurnaceareautomaticallytransportedtotheholdingfurnaceofmoltenmetal,canbeoverheadrail-mounteddispensingdevice,themetalflowtroughdeliverydevicescanalsobeusedmetalblocktransferdispensingdevice.8. environmentalprotection,pollutioncontrold
22、eviceCastingproductionprocess,thesmeltingofmetals,lubricantspracleaning,heatradiationandmoltenmetalmolds,diecastingmachinediecastingoperation,etc.,willproduceharmfulgases,smoke,dust,heat,oilandnoise,thesearetheenvironmentandhumanhealtheffectsandpollution.Tothisend,theneedsandconditions,firstfromthes
23、tart,anddecreasedpollution.Then,takethenecessarycontrolmeasures.Becausecastingproductionofhighlyspecialized,requiresgovernanceandenvironmentalaspectsaremorepresent,mostenterprisesareequippedwithfirstmeansevacuatingsmokeandwastewaterinstallationsstart.Somecitieshavehigherrequirementsforenvironmentalp
24、rotection,notallowedtosmokeoutsidetheplanttoanyemissions,youalsoneedadditionalsmokefiltersandcleaningapparatus9. PowerequipmentDie-castingproductionneedspowersourcesincludeelectricity,gas,water.Typically,accordingtoconventionalequipment.Powerrequirements(1)thepowersupplyisgenerallysupplied:three-pha
25、sefive-wiresystem,theexchange380,50HZ,groundingresistance1zifnecessarywiththecorrespondingcapacityofpowersupplydevices.(2) Whenusingagasfurnace,therequiredconfigurationsupplied.(3) aircompressor,whennecessary,acorrespondingvolumeofcompressedair;compressedairpressure0.4-0.6MPa.(4) watersupplyapparatu
26、s,waterpressure0.2MPa.Forwhenyouneedtowaterrecycling,thereshouldbeconfiguredwatercoolingtower.10. TheplantenvironmentalfacilitiesCastingproductionbelongstothehotwork,shouldprovideagoodworkingenvironment,inlinewithindustrialhygienerequirements,tomeetthesafetyandsecurityoftheplantoperator.Measureslike
27、:heatingheating,exhaustventilation,lightingandlightingandsoon,canbeconfiguredwiththeappropriateamenitiesdependingonregionalandlocalclimate.11. )Theproductionofdie-castingplantCastingproductiontotheplantrequirementsasfollows:1. MainBuildingWhenthecompositionofthesurroundingdie-castingunit,pressthepro
28、ductionofthedesiredproductsrequireautomatedproductionlines;(1)MainBuildingofdiecastingmachine,die-castingmachinesaswellastheholdingfurnace(referredtoasthehost)supportingassistivedevicesandperipheralsrequiredpartcompleteequipment.(2) layingforvariousequipmentandapparatusshallbeequippedwithcables,pipe
29、s.Sincethenpeopleplantafterthemaincable,themainchannel,inadditiontothecranecableandlightingplacedabovethecranetrack,therestofthecable,pipelayingareinuseunprotectedburiedundergroundwayisappropriate.Branchcableconnectedtothemachine,pipingandevenmoreso,inordertoavoidinterferencewiththecranetransportorp
30、eripherals.Egressinterfacewiththehostlocationofallcableandrelatedequipment,pipesshallcomplywiththerequirementsofthespecificationdiecastingmachines,devicesandequipment.(3) die-castingmachinesandsupportingequipmentandapparatus(hereinafterreferredtoasmachines,die-castingunitlikewise)asrequiredclothrow.
31、(4) themachineisnotonlyanareaofthedeviceaccordingtothespecificationrequirements,butalsoleavesufficientroom.(5) Whenthemachineisconnectedtomoreandwhenthearrangementshouldbemadedifferentarrangements(seeprocesslayout)accordingtothespanoftheplant.(6) Forthesupplementaryliquidmetalfromthemeltingfurnaceto
32、theholdingfurnaceapproachistheuseofautomatedtransport,whetheratthetoporontheground,cannotbeplacedwithinthespatialrangeofthemainchannel,toensuresafeandunimpededmainchannel.Itcannotoccurandinterferewiththeoperationofspacetorunandliftthecrane.(7) Theheightofthemainbuilding:theneedtocraneliftingheight(i
33、ncludingmaximumliftinglargestmoldparts,machineryorequipment)todeterminethepositionofthecranetracksurface,pressthetopofthecranebuildingheightrequirementstobedetermined.Typically,theclampingforceof1,000tonsofdiecastingmachine,theheightofthecranetracksurfacewhichisapproximately8.5misappropriate,largerm
34、odelsshouldbehigher.(8) shouldbesetupwithinthemainplantenvironmentalcontroldevices,aswellastomaintainthehealthoftheplanttoprovideagoodworkingenvironmentandfacilities.Whereintheexhaustventilationsystemisthemostcritical,craneabovetheBuildingstructureandroofstructureshallbeselectedandrequestedexhaustve
35、ntilationsystemstoadaptandmatch.2. meltbetweenRoom(1) meltingmoltenmetalisconcentratedworkplacescentralizedmeltingoperationsonlytomeetmorethanonediecastingmachinefortheamountofliquidmetal,andeasytoguaranteethequalityofthemoltenmetal.(2) theproductionofmorethantwokindsofalloygrades(inclusive),thearea
36、betweenthemoltenalloymustmeetthedifferentgradesofclassification,classificationmanagementrequirements.(3) shouldbeclosetothemeltingaskthemainplantandshouldpartitioncanbeapartofthemainbuilding,whichislocatedatoneendpositiontothelongitudinaldirectionofthemainplantisappropriatetofacilitatethedeliveryofm
37、oltenmetaltotherespectivemachineinsulationfurnace.(4) powersourcesshouldbebasedonthechoicebetweenthemeltingfurnacerequirements.(5) betweenthemeltingshouldseparateliftingequipment,loading,feedingdevices.(6)shouldhavesufficientpowersupplyandventilationmeansforevacuatingsmoke.3. clearingplant(1) cleari
38、ngoftheplantcontainmanualoperationportionandmachineparts.Whenallhaveformsofproductionorautomatedproductionlinesdie-castingunitdoesnothavetocleartheentireplant,butthereisstillengagedintheartificialjobsite.Somecompanieswerecastingtheappearanceofproprietaryvisualinspectionprocess(usuallyreferredtoasthe
39、subjectsub-step),theappearanceofunqualifieddiecastings(waste)rejectit.Inthisregard,itisoftenthesubjectofsub-stepjobsiteontheclearovertheentireplant.(2) clearingthewayclearingtheareaofworkrelatedtotheentireplant,especiallywiththeuseofthetrimmer;thetypeandquantityofmachineryandequipmentrelated.Whenhas
40、aconsiderablenumberofthemachineafterthemanualcleaningonfeweroperatingareacanbemuchsmaller;cleanupworkisrelativelyless,andcleanhighefficiency,qualityisrelativelystable.(3) clearingoftheplantshouldbenearorconnectedtothemainbuilding,easytotransportdiecastings.Clearingplantheightcanbelowerthanthemainpla
41、nt,lightplantrequirementscanbebuilt.(4) whenthealloyproducttypesandgradesofmorethanonekindofcase,inordertofacilitatethedifferentalloysorting,gradingmanagement,clearingforthisplantshouldallowsufficienttemporarystoragearea.(5) Forsomediecastings,intheclearingprocess,theremaybeapartialclearingofthesite
42、oftheprocessandthesubsequentmachiningstepmerge。sothatthepartsdirectlytothefinishedsize.Atthesametime,alsofacilitatethetransferpriortocasting,tounderstandthesituationporespresentonthesurfaceoftheprocessingsite.Tothisend,intheclearingoftheplantneedforadditionalhighprecisionmachiningequipment(nowmostly
43、CNCmachiningcenters),then,intheclearingoftheplantshouldbefinishedinaseparatevenue.4. PlantSubsidiaryAffiliatedworkshopfordie-castingproductionsitessupportingtechnology,management,maintenance,andlifeneeds.Inthemainplantlocatedinthesamebuildingasthemainbodyisappropriate,itcanbemorecentrallylocatedinth
44、esamesideofthemainbuilding.(1) MetalMaterialLibrarymetalingotmaterialstorageyardandplantshouldhavethesamerequirements.Whenthetypeofalloygradesandmore,shouldstrengthenmanagement,andstrictandbeclassifiedaccordingtothetypeofalloygrades,grading,maynotcrossmixed.Ingotmaterialshouldbeavoidedbythewetdamp,i
45、nordertoavoidmildew,reducingthequalityofthealloymaterial,affectthequalitydiecastings.Inordertofacilitatethetransportposition,thelibrarymaterialsascloseasmeltingbetweenappropriate.(2) thefinishedproductstobetestedtoconfirmmanagementasaqualifiedcastingintothefinishedproducts,andthenloadedintototesoras
46、required(basket)tobetransportedtothefollowingprocess,packingorpackagingtobeshipped.(3) theareashouldbesufficienttomoldlibrarymanagementsystemneatlystackedbythemolddie.Andalsoanotherareatofacilitatecertainjobscarrylinecare(washing,cleaning,coatingoil)andsimplemaintenance(grinding,replacementofwearing
47、parts,etc.)work.Also,specialequipmentandtechnologyrelatingtomoldordie-castingprocess,alsowiththemoldaccordingtothesystemasproperstorageandmanagement.(4) detectiontestcenter,alsoknownasthestudio,includingworkmeasurementandphysicalandchemicaltesting,andrelativelyfewcasesunderthefacility,locatedinthesa
48、mebuildingwiththemainbodyplant.Forqualifiedenterprises,morecompleteinstrumentandequipment,measurement,physicalandchemicallaboratorycanalsosetupaseparatebodyintheheatedbuilding.(5) isadie-castingmachinesparepartsandspareandwearpartsstorageandmanagementofotherequipmentpremises.Conditions,canalsocatert
49、othemachinewithaservicestationatthesametime.Dependingonthenumberandareaofitsmaintenanceworkloadofspareandwearparts(thenumberofunitsandthediecastingmachineandotherequipmentrelated)maybe.(6) Thetoollibraryiscastingproductionprocesseachstepofvarioustoolsusedinthestorageandmanagementofpremises.Instrumentsreferredtoinclude:theoperatorshandtools,generaltools,specialtoolsandspecialprocessequipment.(7) tostoresomelibrarymaterialsconsumablescastingpro
