MANAGEMENT SYSTEM AND MANAGEMENT METHOD

- SINTOKOGIO, LTD.

A management system includes: an acquisition unit acquiring melting information pertaining to original molten metal, for each of melting furnaces; a first assignment unit assigning a ladle serial number to a ladle receiving the original molten metal; a melting management unit associating a furnace number, the number of tappings from the one melting furnace, and the melting information on the one melting furnace with each other, and storing associated items; a ladle management unit associating the ladle serial number, the furnace number, and the number of tappings with each other, and storing associated items in a storage medium; and a pouring management unit associating an identifier of the mold with the ladle serial number, in response to the pouring device pouring the molten metal in the conveyed ladle into the mold, and storing associated items in the storage medium.

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Description
TECHNICAL FIELD

This disclosure relates to a management system and a management method.

BACKGROUND ART

In a casting plant, various types of facilities operate until products are obtained. A molding device forms a mold. A conveyance device conveys the mold to a pouring place. A melting furnace melts a material and obtains original molten metal. A ladle receives the original molten metal from the melting furnace. The conveyance device conveys, to the pouring place, the ladle having received the molten metal. The pouring device pours the molten metal from the ladle into the mold at the pouring place.

Patent Document 1 discloses a management device that manages data in the casting plant described above. This device associates the mold position with the mold serial number of the mold at the mold position, by shifting the mold serial number to be assigned to the mold position dynamically with reference to the movement of the mold detected by a sensor. This device associates data pertaining to the mold with data on the molten metal, by associating the mold serial number with the ladle serial number.

CITATION LIST Patent Document

Patent Document 1: WO2017/085765

SUMMARY OF INVENTION Technical Problem

Incidentally, in the casting plant, a plurality of melting furnaces may in some cases prepare original molten metal. Furthermore, the melting furnaces can prepare several ladles of the original molten metal. Accordingly, in order to track causes and the like of occurrence of a failure of the mold in detailed manner, information pertaining to the mold is required to be associated with information on the original molten metal. This disclosure provides a management system and a management method that can manage information obtained from a melting step to a pouring step.

Solution to Problem

One aspect of this disclosure is a management system for a casting facility. A casting facility taps, into a ladle, a part of original molten metal obtained in one melting furnace among melting furnaces, adjusts a component of the original molten metal in the ladle having received the original molten metal to obtain molten metal, conveys the ladle retaining the molten metal to a pouring device, and pours the molten metal in the conveyed ladle into a mold using the pouring device. The management system includes: an acquisition unit; a first assignment unit; a melting management unit; a ladle management unit; and a pouring management unit. The acquisition unit acquires melting information pertaining to the original molten metal for each of the melting furnaces. The first assignment unit assigns a ladle serial number to the ladle receiving the original molten metal. The melting management unit associates a furnace number identifying the one melting furnace, the number of tappings from the one melting furnace, and the melting information on the one melting furnace with each other, and stores associated items in a storage medium. The ladle management unit associates the ladle serial number, the furnace number, and the number of tappings with each other, in response to tapping of the original molten metal from the one melting furnace into the ladle, and stores associated items in the storage medium. The pouring management unit associates an identifier of the mold with the ladle serial number, in response to the pouring device pouring the molten metal in the conveyed ladle into the mold, and stores associated items in the storage medium.

According to the management system according to the one aspect, the melting information pertaining to the original molten metal is obtained for each of the melting furnaces. The melting information, the furnace number, and the number of tappings are associated with each other, and are stored in the storage medium. Furthermore, the ladle serial number, the furnace number, and the number of tappings are associated with each other, in response to tapping of the original molten metal from one melting furnace to the ladle, and are stored in the storage medium. The ladle serial number is associated with the identifier of the mold at the time of pouring. As described above, according to the management system according to the one aspect, the melting information can be managed in a unit of a ladle, using the furnace number and the number of tappings. By associating the furnace number and the number of tappings with the ladle serial number, the management system according to the one aspect can associate, with the melting information, information on subsequent steps managed in a unit of a ladle, such as adjustment of the component of the original molten metal, conveyance, and pouring. Consequently, the management system according to the one aspect can manage information obtained from the melting step to the pouring step.

In an embodiment, the ladle may include a processing ladle receiving the original molten metal, and a plurality of pouring ladles receiving transferred contents from the processing ladle, and the casting facility may transfer contents from the processing ladle into one pouring ladle among the pouring ladles. The management system may further include a second assignment unit assigning the ladle serial number of the processing ladle to the one pouring ladle in response to transfer of the contents of the processing ladle into the one pouring ladle. In this case, after the original molten metal is tapped, the ladle serial number is passed from the processing ladle to the pouring ladle together with the molten metal. As described above, even if the ladle is transferred, the information obtained from the melting step to the pouring step can be managed.

In an embodiment, the ladle management unit may associate information on a first inoculation material injected into the processing ladle in order to adjust a component of the original molten metal, with the ladle serial number, and store associated items in the storage medium. In this case, through the ladle serial number, the furnace number, and the number of tappings, the melting information can be associated with information on the first inoculation material.

In an embodiment, the ladle management unit may associate information on a second inoculation material injected into the pouring ladle in order to adjust a component of molten metal, with the ladle serial number, and store associated items in the storage medium. In this case, through the ladle serial number, the furnace number, and the number of tappings, the melting information can be associated with the information on the second inoculation material.

In an embodiment, an identifier identifying the pouring ladle, and the ladle serial number may be associated with each other, and stored in the storage medium. In this case, the pouring ladle can be uniquely identified from the ladle serial number.

In an embodiment, the casting facility may include a plurality of ladles conveying the molten metal to the pouring device. In this case, when one ladle moves to a receiving position for the sake of receiving molten metal, the casting facility can allow another ladle having already received molten metal, to a pouring position. Accordingly, when the one ladle moves to the receiving position for the sake of receiving molten metal, a line for pouring is not required to be stopped. Consequently, in comparison with a case of using one ladle, the casting facility can continue longer a state capable of pouring. Through use of a plurality of ladles, molten metal being transferred and molten metal to be poured in actuality are in a state of being allowed to reside at the same time. According to the management system, by associating the ladle serial number, the furnace number, and the number of tappings with each other and storing the associated items, the relationship between the original molten metal and the ladle can be managed even in such situations.

Another aspect of this disclosure is a management method in a casting facility. A casting facility taps, into a ladle, a part of original molten metal obtained in one melting furnace among melting furnaces, adjusts a component of the original molten metal in the ladle having received the original molten metal to obtain molten metal, conveys the ladle retaining the molten metal to a pouring device, and pours the molten metal in the conveyed ladle into a mold using the pouring device. The management method includes: an acquisition step; a first assignment step; a melting step; and a pouring management step. The acquisition step acquires melting information pertaining to the original molten metal for each of the melting furnaces. The first assignment step assigns a ladle serial number to the ladle receiving the original molten metal. The melting management step associates a furnace number identifying the one melting furnace, the number of tappings from the one melting furnace, and the melting information on the one melting furnace with each other, and stores associated items in a storage medium. The ladle management step associates the ladle serial number, the furnace number, and the number of tappings with each other, in response to tapping of the original molten metal from the one melting furnace into the ladle, and stores associated items in the storage medium. The pouring management step associates an identifier of the mold with the ladle serial number, in response to the pouring device pouring the molten metal in the conveyed ladle into the mold, and stores associated items in the storage medium.

In the management method according to the other aspect, advantageous effects identical to those of the management system according to the one aspect can be exerted.

Advantageous Effect of Invention

According to various aspects and embodiments of this disclosure, the information obtained from the melting step to the pouring step can be managed.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a plan view showing an example of a configuration of a casting facility.

FIG. 2 is a side view of an example of a primary inoculation device.

FIG. 3 is a side view of an example of a receiving bogie.

FIG. 4 is a side view of the example of the receiving bogie.

FIG. 5 is a side view of an example of a secondary inoculation device.

FIG. 6 shows an example of a measurement unit of the primary inoculation device or the secondary inoculation device.

FIG. 7 is a side view of an example of a conveyance bogie.

FIG. 8 is a side view of the example of the conveyance bogie.

FIG. 9 is a side view of an example of a pouring device.

FIG. 10 is a side view of the example of the pouring device.

FIG. 11 shows an example of dogs for a sensor of detecting a ladle number of a pouring ladle.

FIG. 12 shows an example of the sensor of detecting the ladle number of a pouring ladle.

FIG. 11 shows an example of a table used for detecting the ladle number.

FIG. 14 is a block diagram showing an example of a hardware configuration of a management system.

FIG. 15 is a flowchart showing an example of each of steps from a melting step to a pouring step.

FIG. 16 shows an example of operations of the casting facility.

FIG. 17 shows an example of operations of the casting facility.

FIG. 18 shows an example of information acquired from the casting facility.

FIG. 19 shows an example of a data structure that the management system has.

FIG. 20 is a plan view showing another example of the configuration of the casting facility.

FIG. 21 is a plan view showing another example of the configuration of the casting facility.

FIG. 22 is a plan view showing another example of the configuration of the casting facility.

 DESCRIPTION OF EMBODIMENTS

Hereinafter, referring to the drawings, exemplary embodiments are described. In the following description, identical or corresponding elements are assigned the same symbols, and redundant description is not repeated.

[Overview of Management System]

A management system according to an embodiment is a system that integrally manages information obtained from a melting step to a pouring step in a casting facility that manufactures cast products. The melting step is a step of melting a melting material and obtaining original molten metal. The melting step may include a step of inspecting the original molten metal. The melting step performs information processing (data collection, processing and the like) independent from a subsequent step.

The subsequent step can include an inoculation step of adjusting the component of the original molten metal, and a conveyance step of conveying a ladle. Information on these steps is managed in a unit of a ladle. The management system according to the embodiment synchronizes information obtained in the melting step with information on the steps managed in a unit of a ladle.

The pouring step is a step of pouring into a mold. The pouring step manages information using a mold serial number (issued when a mold is formed). The management system according to the embodiment synchronizes information obtained in the pouring step with information on the steps managed in a unit of a ladle. Accordingly, the management system according to the embodiment integrally manages the information obtained from the melting step to the pouring step.

[Example of Casting Facility]

First, an example of a casting facility to which the management system according to the embodiment is applicable is described. A casting facility taps, into a ladle, a part of original molten metal obtained in one melting furnace among melting furnaces, adjusts a component of the original molten metal in the ladle having received the original molten metal to obtain molten metal, conveys the ladle retaining the molten metal to a pouring device, and pours the molten metal in the conveyed ladle into a mold using the pouring device. Hereinafter, as an example, a casting facility that transfers the contents of ladles is described.

FIG. 1 is a plan view showing an example of a configuration of the casting facility. In FIG. 1, a horizontal direction is illustrated as an XY direction, and a vertical direction is illustrated as a Z direction. As shown in FIG. 1, the casting facility 1 is a transfer ladle conveyance scheme facility. The casting facility 1 includes: a plurality of melting furnaces 2; a primary inoculation device 3; a receiving bogie 4 that conveys a processing ladle L1 along first rails R1; a secondary inoculation device 5; a conveyance bogie 6 that conveys a pouring ladle L2 along second rails R2; a ladle replacement device 7; and a pouring device 8.

The plurality of melting furnaces 2 include, for example, a first melting furnace 21 and a second melting furnace 22. The first melting furnace 21 and the second melting furnace 22 may have the same configuration, or different configurations. Hereinafter, description is made, assuming the first melting furnace 21 as a representative of the melting furnaces 2. The first melting furnace 21 is a device that melts melting materials with heat, and obtains original molten metal. Examples of the melting materials are pig iron, return material, steel scrap, alloy material and the like. The first melting furnace 21 is, for example, an electric furnace, or a cupola, and may be any furnace only if it can melt the melting material; there is no limitation. Corresponding melting material injection devices 23 and 24 are juxtaposed with the first melting furnace 21 and the second melting furnace 22, respectively and the melting material is injected into the furnaces by the melting material injection devices 23 and 24. The operations of the melting material injection device 23 and 24 are controlled by an after-mentioned melting material measurement and injection device PLC (Programmable Logic Controller) 103 (FIG. 14). In general, the first melting furnace 21 can obtain, at a time, a certain amount of original molten metal, the amount allowing the original molten metal to be tapped into an after-mentioned receiving ladle multiple times. That is, the retaining amount of the original molten metal in the first melting furnace 21 is larger than the retaining amount of the receiving ladle.

The melting furnaces 2 are juxtaposed with the first rails R1 of the receiving bogie 4 (Y direction in the diagram). Accordingly, the processing ladle L1 can receive molten metal from any of the melting furnaces. The melting furnaces 2 may be three of more melting furnaces.

The operations of the melting furnaces 2 are controlled by an after-mentioned melting furnace PLC 104 (FIG. 14). The melting furnaces 2 are provided with a temperature sensor 105 (FIG. 14), and can acquire the temperature of the original molten metal. The molten metal of the melting furnaces 2 can be sampled for a component inspection, and can be inspected, in an inspection chamber 9, by a carbon analysis device 106 (FIG. 14), a Quantovac element analysis device 107 (FIG. 14), a CE meter 108 (FIG. 14) and the like.

The primary inoculation device 3 is a device that adjusts the component of the original molten metal received by the processing ladle L1. The primary inoculation device 3 injects materials to be added to the original molten metal, into the processing ladle L1. The primary inoculation device 3 is juxtaposed with the first rails R1 of the receiving bogie 4 (Y direction in the diagram). Hereinafter, a position at which the dopant material is injected by the primary inoculation device 3 is also called a primary inoculation position P1. The dopant material is added to the molten metal in order to increase the strength, toughness, or corrosion resistance, heat resistance, abrasion resistance or the like of cast iron. Examples of the dopant material include Mg, Ce, Ca, Ni, Cr, Cu, Mo, V, Ti and the like. The dopant material may include a graphite spheroidizing agent. The primary inoculation device 3 may add an inoculation agent, such as calcium silicon, ferrosilicon, graphite or the like.

FIG. 2 is a side view of an example of the primary inoculation device. As shown in FIG. 2, the primary inoculation device 3 includes primary inoculation alloy hoppers 31, alloy measurement devices 32 (an example of a measurement unit), a conveyor belt 33, and an injection chute 34. The primary inoculation alloy hoppers 31 are containers that store respective dopant materials. Examples of the dopant materials are alloys. The primary inoculation alloy hoppers 31 are prepared for the respective types of dopant materials. The alloy measurement devices 32 are provided below the respective primary inoculation alloy hoppers 31. The alloy measurement devices 32 are devices that measure dopant materials to be injected, and adjust the amounts to be added. The amounts of dopant materials adjusted by the respective alloy measurement devices 32 are supplied from the primary inoculation alloy hoppers 31 onto the conveyor belt 33. The conveyor belt 33 collects the supplied dopant materials into the injection chute 34. When the receiving bogie 4 mounted with the processing ladle L1 reaches the primary inoculation position P1, the processing ladle L1 is positioned below the injection chute 34. The injection chute 34 injects the dopant materials into the processing ladle L1. The primary inoculation device 3 injects the dopant materials into the processing ladle L1 before the original molten metal is received. Note that the primary inoculation device 3 may have any configuration only if this device can add required dopant materials to the original molten metal. The primary inoculation device 3 may inject the dopant materials after the original molten metal is received. The operation of the primary inoculation device 3 is controlled by an after-mentioned primary inoculation device PLC 201 (FIG. 14).

The receiving bogie 4 is mounted with the processing ladle L1, and conveys the processing ladle L1 along the first rails R1 (Y direction in the diagram). The receiving bogie 4 can be stopped not only at the primary inoculation position P1 described above, but also at a receiving position P2 from the first melting furnace 21 and a receiving position P3 from the second melting furnace 22. The receiving bogie 4 may have a transfer function. Transfer means transfer of molten metal to another ladle. The receiving bogie 4 can stop at a transfer position P4, and transfer the retaining molten metal into the pouring ladle L2.

FIGS. 3 and 4 are side views of an example of the receiving bogie. As shown in FIGS. 3 and 4, the receiving bogie 4 includes a ladle tilting mechanism 41, a weight measurement mechanism 42, and a non-contact thermometer 43. The ladle tilting mechanism 41 rotationally tilts the processing ladle L1 about a rotational axis extending in a direction (Y direction in the diagram) along the first rails R1. Accordingly, the molten metal can be transferred into the pouring ladle L2 at the transfer position P4. The weight measurement mechanism 42 is a mechanism including a sensor that measures the receiving amount of original molten metal. The weight measurement mechanism 42 includes, for example, a load cell. The non-contact thermometer 43 is a sensor that measures the temperature of the original molten metal in a non-contact manner. The receiving bogie 4 may include an encoder at a wheel, thereby measuring the rotation of the wheel, that is, traveling. Accordingly, the position of the processing ladle L1 is detected. The receiving bogie 4 may include another position detection sensor, such as a photoelectric sensor. The operation of the receiving bogie 4 is controlled by an after-mentioned receiving bogie control device PLC 203 (FIG. 14).

The secondary inoculation device 5 is a device that adjusts the component of the molten metal retained in the pouring ladle L2. The secondary inoculation device 5 injects materials to be added to the molten metal into the processing ladle L1. The dopant materials are injected when the molten metal is transferred from the processing ladle L1 into the pouring ladle L2, which can uniformly inject the dopant materials in a short time period. Furthermore, since the receiving bogie 4 can measure the weight of the molten metal, the dopant materials can be injected such that the ratio between the molten metal and the materials (injected material ratio) can be correct.

FIG. 5 is a side view of an example of the secondary inoculation device. As shown in FIG. 5, the secondary inoculation device 5 includes secondary inoculation alloy hoppers 51, an alloy measurement device 52 (an example of the measurement unit), a conveyor belt 53, and an injection chute 54. The secondary inoculation alloy hoppers 51 are containers that store respective dopant materials. Examples of the dopant materials are alloys. The secondary inoculation alloy hoppers 51 are prepared for the respective types of dopant materials. The alloy measurement device 52 are provided below the respective secondary inoculation alloy hoppers 51. The alloy measurement device 52 is the same as the alloy measurement device 32. The amounts of dopant materials adjusted by the respective alloy measurement device 52 are supplied from the secondary inoculation alloy hoppers 51 onto the conveyor belt 53. The conveyor belt 53 collects the supplied dopant materials into the injection chute 54. When the conveyance bogie 6 mounted with the pouring ladle L2 reaches the transfer position P4, the pouring ladle L2 is positioned below the injection chute 54. The injection chute 54 injects the dopant materials into the pouring ladle L2. Note that the secondary inoculation device 5 may have any configuration only if this device can add required dopant materials to the molten metal. The operation of the secondary inoculation device 5 is controlled by an after-mentioned secondary inoculation device PLC 202 (FIG. 14). Note that the secondary inoculation device 5 may be provided for the receiving bogie 4.

FIG. 6 shows an example of the primary inoculation device or the secondary inoculation device. As shown in FIG. 6, a load cell 64 is provided below the alloy hopper 61. An electromagnetic feeder 62 and a hopper gate 63 are provided below the load cell 64. The measurement unit causes the load cell 64 to perform measurement, operates the electromagnetic feeder 62 and the hopper gate 63, and supplies a predetermined amount of material from the alloy hopper 61.

The conveyance bogie 6 is mounted with the pouring ladle L2, and conveys the pouring ladle L2 along the second rails R2 (X direction in the diagram). The conveyance bogie 6 can be stopped not only at the transfer position P4 described above, but also at a ladle replacement position P5 where the pouring ladle L2 is conveyed to the pouring device 8. The conveyance bogie 6 may have a function capable of changing a direction of the pouring ladle L2.

FIGS. 7 and 8 are side views of an example of the conveyance bogie. As shown in FIGS. 7 and 8, the conveyance bogie 6 includes a traveling bogie 71 that travels on the second rails R2, and a bogie travel mechanism 72 that causes the traveling bogie 71 to travel. The bogie travel mechanism 72 is a travel motor. The traveling bogie 71 is provided with roller conveyers 73 and 74 that cause the pouring ladle L2 to travel in a horizontal direction, and a swing mechanism 75 that turns the pouring ladle L2 while the ladle is kept mounted. By the swing mechanism 75, a direction of a nozzle L21 of the pouring ladle L2 is changed. The conveyance bogie 6 may include an encoder at a wheel, thereby measuring the rotation of the wheel, that is, traveling. Accordingly, the position of the processing ladle L1 is detected. The conveyance bogie 6 may include another position detection sensor, such as a photoelectric sensor. The operation of the conveyance bogie 6 is controlled by an after-mentioned ladle conveyance bogie control device PLC 204 (FIG. 14).

The ladle replacement device 7 is a device that is provided on a previous stage (ladle replacement position P5) of the pouring device 8, and replaces a pouring ladle (filled ladle F) in which molten metal is present with a pouring ladle (empty ladle E) which is empty after pouring. The ladle replacement device 7 includes a roller conveyor that allows the empty ladle E to stand by (empty ladle standby position P6), and a roller conveyor that receives the filled ladle F on the conveyance bogie 6 (filled ladle standby position P7). The pouring device 8 slides in a direction where the empty ladle standby position P6 and the filled ladle standby position P7 provided in parallel (X direction in the diagram), thereby achieving replacement. For example, the pouring device 8 slides to the empty ladle standby position P6, thereby allowing the empty ladle E to be passed from the pouring device 8 to the empty ladle standby position P6. The filled ladle F is conveyed from the conveyance bogie 6 to the filled ladle standby position P7. The pouring device 8 slides to the filled ladle standby position P7, thereby allowing the filled ladle F to be passed from the filled ladle standby position P7 to the pouring device 8.

The pouring device 8 is a device that pours, into a mold, the molten metal retained in the pouring ladle L2. The pouring device 8 is provided lateral to the mold rails R3. The pouring device 8 pours the molten metal in the pouring ladle L2, into the mold conveyed on the mold rails R3.

The mold rails R3 are rails for conveying the mold from a molding device (not shown) and for cooling and conveying the mold poured with the molten metal to a shake-out device (not shown). The mold rails R3 include first mold rails R31, and second mold rails R32. The first mold rails R31 and the second mold rails R32, for example, extend linearly along the X direction in the diagram, and are arranged in parallel.

The first mold rails R31 are rails for conveying the molds to the pouring device 8. A pair of mold feeding devices 11 (pusher and cushion) are arranged on the opposite ends of the first mold rails R31. The pusher, which constitutes the mold feeding device 11, has a function of pushing the molds and the cushion, which constitutes the mold feeding device 11, has a function of receiving the pushed molds. The molds can be fed without any gap by the pusher and cushion. The mold feeding devices 11, which include the pushers and the cushions, feed the mold in a unit of a mold frame. In FIG. 1, only the mold feeding device (cushion) at the front end of the first mold rails R31 is illustrated. Illustration of the mold feeding device (pusher) disposed on the rear ends of the first mold rails R31 is omitted. The mold feeding devices 11 are devices that include expandable and contractible rods, and are, for example, servo-cylinders. The pair of mold feeding devices 11 interpose therebetween a row of molds on the first mold rails R31, which operate in synchronization according to a predetermined speed curve. Specifically, the mold feeding device (pusher), which is disposed on the rear end of the first mold rails R31, extends the rod to thereby push the mold on the rear end arranged on the first mold rails R31 by one frame, thus intermittently conveying the mold by one frame. The mold feeding device (cushion), which is disposed on the front end of the first mold rails R31, operates in such a way as to contract the rod in conformity with the mold on the rear end being pushed by the pusher. According to such a configuration, even during conveyance, the row of mods can be pressed on the opposite ends. Accordingly, the mods are stable even during conveyance, and vibration-damping control can also be achieved.

The molds on the first mold rails R31 are conveyed in the negative sense of X in FIG. 1. When the mold reaches the front end of the first mold rails R31, they are moved onto the second mold rails R32 by a traverser. The second mold rails R32 are rails for conveying the molds to the shake-out device. Similar to the first mold rails R31, a pair of mold feeding devices 11 (pusher and cushion) are arranged on the opposite ends of the second mold rails R32. In FIG. 1, only the mold feeding device (pusher) at the rear end of the second mold rails R32 is illustrated. Illustration of mold feeding device (cushion) disposed on the front end of the second mold rails R32 is omitted. The operation of the mold feeding device at the second mold rails R32 are the same as the operation of the mold feeding device at the first mold rails R31. The molds on the second mold rails R32 are conveyed in the direction opposite to the conveyance direction of the molds on the first mold rails R31, that is, the positive sense of X in FIG. 1. The mold after pouring is cooled over time on the second mold rails R32, and the molten metal is solidified and becomes a casting before reaching the shake-out device. The mold feeding devices 11 may include a mold position sensor that detects expansion and contraction of the rod, and detects conveyance of the mold. An example of the mold position sensor is a limit switch or a proximity switch. Mold conveyance is controlled by an after-mentioned mold line PLC 400 (FIG. 14). If the pouring device 8 and mold conveyance are required to be synchronized with each other, an encoder, a length measurement sensor or the like is disposed at the mold rails R3. The pouring device 8 is controlled based on the conveyance speed and position of the mold acquired using the sensor in such a way as to be synchronized with conveyance of the mold.

FIGS. 9 and 10 are side views of an example of the pouring device. As shown in FIGS. 9 and 10, the pouring device 8 includes: a pouring device bogie 81 that travels on pouring device rails R4 laid in parallel with the mold rails R3; a vertically moving mechanism 82 provided on the pouring device bogie 81; and a tilting mechanism 83 that is supported by the vertically moving mechanism 82 and tilts the mounted pouring ladle L2. The vertically moving mechanism 82 is provided on a front and rear movement mechanism 84 that moves in a direction orthogonal to a direction in which the pouring device bogie 81 travels. The pouring device 8 may include a load cell 85 that measures the weight of the molten metal in the pouring ladle L2, and a non-contact thermometer (not shown) that measures the temperature of the molten metal to be poured. The operation of the pouring device bogie 81 is controlled by an after-mentioned pouring device bogie PLC 301 (FIG. 14). The operation of the pouring device 8 is controlled by an after-mentioned pouring device main PLC 300 (FIG. 14).

The pouring device 8 may include a test piece (TP) collection unit that receives the molten metal for a test piece (TP) from the pouring ladle L2. The TP collection unit collects TP from the molten metal in each pouring ladle L2 for material inspection.

The casting facility 1 may include a sensor that recognizes a ladle number (an example of an identifier of the pouring ladle) that is an individual number of the pouring ladle L2. FIG. 11 shows an example of dogs for a sensor of detecting the ladle number of the pouring ladle. FIG. 12 shows an example of the sensor of detecting the ladle number of the pouring ladle. As shown in FIG. 11, on the bottom of the pouring ladle L2, dogs S1 to S4 readable by the sensor of detecting the ladle number are arranged in conformity with the individual number. As shown in FIG. 12, the sensor 77 of detecting the ladle number is provided on the roller conveyor (filled ladle standby position P7) for receiving the filled ladle F on the conveyance bogie 6, for example.

FIG. 13 shows an example of a table used for detecting the ladle number. As shown in FIG. 13, the ladle numbers 1 to 15 are preliminarily assigned patterns of the dogs S1 to S4, respectively. The sensor 77 of detecting the ladle number reads the pattern of the dogs S1 to S4, thereby recognizing the ladle number, which is the individual number of the pouring ladle L2.

The casting facility 1 includes a ladle position detection sensor (not shown) that detects conveyance of the processing ladle L1 to the aforementioned primary inoculation position P1, the receiving positions P2 and P3, and the transfer position P4, and conveyance of the pouring ladle L2 to the transfer position P4, the ladle replacement position P5, the empty ladle standby position P6, and the filled ladle standby position P7. The ladle position detection sensor may be a proximity switch or a laser sensor that is disposed below the roller conveyor. Alternatively, the sensor may be an encoder or a photoelectric sensor provided for the receiving bogie 4 or the conveyance bogie 6.

[Hardware Configuration of Management System]

FIG. 14 is a block diagram showing an example of the hardware configuration of the management system. As shown in FIG. 14, the management system 10 includes: a melting block B1 that manages information on the melting step; a molten metal conveyance block B2 that manages information on a molten metal conveyance step; a pouring block B3 that manages information on the pouring step; a mold line PLC 400 that manages information on a mold conveyance step; and a casting information management computer 100 that integrally manages the entirety. Each PCL or computer in the diagram is physically configured as a typical computer system that includes a CPU (Central Processing Unit), main memory devices (an example of a storage medium) such as RAM (Random Access Memory) and ROM (Read Only Memory), an input device such as a touch panel or a keyboard, an output device such as a display, and an auxiliary storage medium (an example of a storage medium) such as a hard disk.

The casting information management computer 100 includes a database 110, and integrally manages information on all the steps. The database 110 includes a ladle serial number reference DB, a mold serial number reference DB, and a furnace number and the-number-of-tappings reference DB. The reference means that all the pieces of information in the DB are associated with items serving as references. That is, in the ladle serial number reference DB, all the pieces of information in the DB are associated with the ladle serial numbers. In the mold serial number reference DB, all the pieces of information in the DB are associated with the mold serial numbers. In the furnace number and the-number-of-tappings reference DB, all the pieces of information in the DB are associated with the furnace numbers and the numbers of tappings.

The melting block B1 includes a melting information management computer 101 (an example of the acquisition unit, and an example of the melting management unit). The melting information management computer 101 is a device that integrally manages the information on the melting step. The melting information management computer 101 is communicably connected via a network to the melting material measurement and injection device PLC 103, the melting furnace PLC 104, the temperature sensor 105, the carbon analysis device 106, the Quantovac element analysis device 107, and the CE meter 108. Note that, between the melting information management computer 101 and the carbon analysis device 106, information may be exchanged through manual input by an operator.

The melting information management computer 101 automatically collects information from the connected devices, and stores the information in a database 111. The database 111 can be constructed in the storage medium of the melting information management computer 101. The database 111 is managed with reference to the furnace number and the number of tappings. That is, all the pieces of information pertaining to the melting step are related to the furnace numbers and the numbers of tappings. The furnace number is a number for identifying the melting furnace. The number of tappings is a number indicating the order of pouring in one melting furnace, for example. The number of tappings may be reset at timing of melting, or a serial number.

The melting information management computer 101 acquires the melting information pertaining to the original molten metal for each of the melting furnaces. The melting information is information that can be obtained in the melting step, and specifically, is information obtainable from the melting material measurement and injection device PLC 103, the melting furnace PLC 104, the temperature sensor 105, the carbon analysis device 106, the Quantovac element analysis device 107, and the CE meter 108. For a more specific example, the melting information includes a molten metal material, the number of melting times, a tapping time point, a melting material type and its injection weight, a primary alloy type and its injection weight, a secondary alloy type and its injection weight, a melting retainment temperature, a melting temperature history code, thermoanalytical data (CE value), Quantovac (elemental analysis result), a carbon analysis result, a tapping temperature, and a tapping weight.

For example, the melting information management computer 101 acquires, from the melting material measurement and injection device PLC 103, information pertaining to the molten metal material, the melting material type and its injection weight, the primary alloy type and its injection weight, and the secondary alloy type and its injection weight. The melting information management computer 101 acquires the molten metal temperature from the temperature sensor 105. The melting information management computer 101 acquires the elemental analysis value from the Quantovac element analysis device 107. The melting information management computer 101 acquires the thermoanalytical data from the CE meter 108. The melting information management computer 101 acquires the carbon analysis value from the carbon analysis device 106. The melting information management computer 101 acquires information that cannot be automatically collected, through input means, such as a keyboard.

Since timings of measuring the pieces of information are different from each other, the melting information management computer 101 associates each piece with the furnace number and registers the associated piece in the database 111 at the corresponding acquisition timing. In response to the original molten metal being tapped from the melting furnace into the processing ladle L1 (i.e., in response to completion of tapping), target data items are integrally read from the database 111, with the furnace number being used as a search key, are associated with the number of tappings, and written in the database 110 (furnace number and the-number-of-tappings reference DB) of the casting information management computer 100. As described above, the melting information management computer 101 associates the furnace number and the number of tappings with the melting information on the melting furnace, and stores the associated items in the storage medium.

The molten metal conveyance block B2 includes a molten metal conveyance control device main PLC 200 (an example of the second assignment unit, and an example of the ladle management unit). The molten metal conveyance control device main PLC 200 is a device that integrally manages the information on the molten metal conveyance step. The molten metal conveyance control device main PLC 200 is communicably connected via the network to the primary inoculation device PLC 201 (an example of the first assignment unit), the secondary inoculation device PLC 202, the receiving bogie control device PLC 203, and the ladle conveyance bogie control device PLC 204.

The primary inoculation device PLC 201 assigns the ladle serial number to processing ladle L1 that receives the original molten metal. For example, the primary inoculation device PLC 201 issues the ladle serial number to the processing ladle L1 at a timing when the processing ladle L1 is positioned at the primary inoculation position P1. The ladle serial number is a number that is assigned to the ladle, and is incremented or decremented. For example, the ladle serial number is zero when start of the casting facility 1 (for example, at a time of start of a daily operation). The ladle serial number is incremented, for example, at a timing when alloy materials for primary inoculation are injected into the processing ladle L1 and the receiving bogie 4 travels toward the receiving position.

The primary inoculation device PLC 201 associates the primary inoculation information with the ladle serial number of the processing ladle L1 of the receiving bogie 4, and transfers the associated items to the storage medium of the molten metal conveyance control device main PLC 200. The primary inoculation information includes, for example, the molten metal material, the alloy injection time point, the alloy type and its weight, the number and time period of uses of the ladle, and the discarded amount of the primary inoculation materials.

The molten metal conveyance control device main PLC 200 shifts the ladle serial number according to the position of the ladle. For example, the molten metal conveyance control device main PLC 200 causes the processing ladle L1 of the receiving bogie 4 to take over the ladle serial number assigned at the primary inoculation position P1, at a timing when the receiving bogie 4 starts and leaves the primary inoculation position P1. In response to transfer from the processing ladle L1 into the pouring ladle L2 of the conveyance bogie 6 (i.e., at a timing of completion of transfer), the molten metal conveyance control device main PLC 200 causes the ladle serial number of the processing ladle L1 of the receiving bogie 4 positioned at the transfer position P4 to be taken over. At a timing when the filled ladle F is conveyed from the conveyance bogie 6 at the filled ladle standby position P7 of the ladle replacement device 7, the molten metal conveyance control device main PLC 200 causes the ladle serial number of the filled ladle F of the conveyance bogie 6 to be taken over as the ladle serial number of the filled ladle F at the filled ladle standby position P7. At a timing when the filled ladle F is moved from the filled ladle standby position P7 of the ladle replacement device 7 to the pouring device 8, the molten metal conveyance control device main PLC 200 outputs the ladle serial number of the filled ladle F at the filled ladle standby position P7 to the pouring device main PLC 300. As described above, the molten metal conveyance control device main PLC 200 shifts the ladle serial number in conformity with the movement of the machine.

The molten metal conveyance control device main PLC 200 stores the ladle serial numbers of the ladle at the primary inoculation position P1, the ladle on the receiving bogie 4, the ladle at the transfer position P4, the ladle on the conveyance bogie 6, and the ladle at the filled ladle standby position P7 of the ladle replacement device 7, in a storage device of the molten metal conveyance control device main PLC 200.

The secondary inoculation device PLC 202 transfers secondary inoculation information to the molten metal conveyance control device main PLC 200. The secondary inoculation information includes, for example, an inoculation time point, the ladle number, the inoculation type and inoculation amount, a Mg reaction completion time, and the discarded amount of secondary inoculation materials. Here, the ladle serial number and the ladle number are associated with each other. The molten metal conveyance control device main PLC 200 associates the ladle serial number of the ladle at the transfer position P4 with the secondary inoculation information, and stores the associated items in the storage medium of the molten metal conveyance control device main PLC 200.

The receiving bogie control device PLC 203 transfers receiving information to the molten metal conveyance control device main PLC 200. The receiving information includes, for example, the molten metal material, the tapping time point, the receiving weight, the receiving temperature, the furnace number, the number of receiving times, and the number of melting times. The number of receiving times is the number of molten metal replenishment times into the ladle. The number of molten metal replenishment times is represented as the number of tappings at the melting furnace and the number is represented as the number of receiving times at the receiving bogie. The molten metal conveyance control device main PLC 200 associates the ladle serial number of the ladle on the receiving bogie 4 with the receiving information, and stores the associated items in the storage medium of the molten metal conveyance control device main PLC 200. Here, the ladle serial number is associated with the furnace number and the number of tappings. That is, the molten metal conveyance control device main PLC 200 associates the ladle serial number with the furnace number and the number of tappings, in response to tapping of the original molten metal from the melting furnace into the processing ladle L1, and stores associated items in the storage medium.

The pouring block B3 includes the pouring device main PLC 300, and the pouring device bogie PLC 301 (an example of the pouring management unit), which are communicably connected to each other. The pouring device main PLC 300 is communicably connected to the casting information management computer 100. The pouring device main PLC 300 is communicably connected to the external mold line PLC 400. The pouring device bogie PLC 301 acquires the mold serial number of a pouring target of the pouring device 8 from the mold line PLC 400 via the pouring device main PLC 300. The pouring device bogie PLC 301 controls the pouring device 8, and collects pouring information. The pouring information includes, for example, the ladle serial number, the mold forming time point, the molten metal material, the casting time point, the receiving passage time point, the receiving pattern number, casting weight, the casting time, the number of times in the ladle, the pouring temperature, the drop in temperature after tapping, the amount of pouring flow inoculation, the fading time, fault information, the pouring machine abnormality information, the test piece serial number, the conveyance time after tapping, and the dust collection time during conveyance. When pouring is completed, the pouring device bogie PLC 301 transmits the pouring information from the pouring device main PLC 300 to the casting information management computer 100, with reference to the mold serial number. That is, in response to pouring of the molten metal in the conveyed pouring ladle L2 by the pouring device 8 into the mold, the pouring device bogie PLC 301 associates the mold serial number (an example of the identifier of the mold) with the ladle serial number, and writes the associated items in the database 110 (mold serial number reference DB) of the casting information management computer 100.

The casting information management computer 100 periodically monitors the melting information management computer 101. A new ladle serial number is issued, and after its data is fixed, the data is stored in a temporary memory of the PLC. The data stored in the temporary memory can be verified through a touch panel or the like. When the last data item for the ladle number is fixed, data items on the ladle serial numbers as targets are integrally read from the molten metal conveyance control device main PLC 200, and are written in the database 110 (ladle serial number reference DB) of the casting information management computer 100.

Since the casting information management computer 100 includes the database 110, the casting information management computer 100 can easily perform data search with reference to the ladle serial number, the mold serial number, and the furnace number and the number of tappings.

[Processing Steps of Casting Facility]

FIG. 15 is a flowchart showing an example of each of steps from the melting step to the pouring step. As shown in FIG. 15, in melting step S1, first, the composition of the melting materials are determined (S10). The composition of the melting materials is determined based on a daily casting instruction, a previous-day composition result, and a recipe. The daily casting instruction includes the original molten metal component, pattern-specific component target value and molten metal material, and an instructed tapping temperature. The previous-day composition result includes the previous-day inoculation amount, and the original molten metal compound ratio. The recipe is a table that associates the pattern of the mold, the material, and the original molten metal with each other.

After the compositions of the melting materials are determined, the required materials are measured based on the composition and are taken (S12). The taken materials are injected by the melting material injection devices 23 and 24 into the melting furnaces 2, and are melted by the melting furnaces 2 (S14).

After start of melting, the temperature of the molten metal is adjusted in the melting furnaces 2 (S16). Samples are collected and various inspections, such as component analysis, are performed, as required (S18). For example, the original molten metal is collected with a cup, and thermoanalysis is applied by the CE meter to the collected original molten metal. Alternatively, the collected original molten metal may be solidified and subsequently broken, and a wavefront inspection in which a break surface is observed by a scanning electron microscope or the like may be performed. Alternatively, the collected original molten metal is brought into the Quantovac chamber, and component analysis may be performed. If lack of carbon is found as a result of various inspections, the carbon adding amount is calculated based on the inspection result (S19). Next, based on the calculated carbon adding amount, carbon is further added (S20). To determine whether the temperature of the original molten metal is tapping temperature or not, the temperature is measured (S22). Steps S10 to S22 constitute the melting step S1.

In parallel to the carbon adding amount calculation step (S19), the results of the component analysis of the original molten metal and the wavefront inspection, and the pattern-specific component target value and molten metal material are compared with each other, and the amount of lack of alloys is calculated (S30). Based on the calculation result of the amount of lack alloys, the required amount of alloy materials is calculated (S32). The calculated amount of alloys are measured and taken, and are injected by the primary inoculation device 3 into the processing ladle L1 on the receiving bogie 4 standing by at the primary inoculation position P1 (S42).

If the original molten metal temperature is the tapping temperature based on the measurement result in step S22, the receiving bogie 4 is moved to the front of the melting furnace 2 (receiving positions P2 and P3) (S44), and a designated weight of the original molten metal is received by the processing ladle L1 on the receiving bogie 4 (S46). After reaction is waited for a certain time period, the receiving bogie 4 is moved to the transfer position P4 (S48 and S50).

In parallel to the above process, the second inoculation alloy amount is calculated and measured in conformity with the molten metal material (S34). Based on the calculation result, the required amount of alloy materials is then calculated (S36).

In response to arrival of the receiving bogie 4 at the transfer position P4, transfer from the processing ladle L1 on the receiving bogie 4 into the pouring ladle L2 on the conveyance bogie 6 is started by the ladle tilting mechanism 41 of the receiving bogie 4. A predetermined weight of the secondary inoculation alloys is injected by the secondary inoculation device 5 into a transfer molten metal flow from the processing ladle L1 into the pouring ladle L2 (S52).

When transfer from the processing ladle L1 into the pouring ladle L2 is completed, the processing ladle L1 is moved to the primary inoculation position P1 and stands by (S40). The conveyance bogie 6 moves to the ladle replacement position P5 (S54). Pouring step S2 is then executed.

In the pouring step S2, first, the empty ladle E having been emptied by pouring is moved to the empty ladle standby position P6. The filled ladle F on the conveyance bogie 6 is then moved to the filled ladle standby position P7 of the ladle replacement device 7. The filled ladle F is passed to the ladle replacement device 7, and is mounted on the pouring device 8 (S56). Also in the pouring step S2, a sample is collected as required (S58), and component analysis is performed (S60). If the component analysis result is out of a predetermined range, notification indicating abnormality is issued, and classification as a fault product is performed at the shake-out device. The conveyance bogie 6 is moved to the empty ladle standby position P6, receives the empty ladle E, and moves to the transfer position P4 to replenish the molten metal (S68). Note that the inoculation weight is determined based on the molten metal material and on the casting weight, and the pouring flow inoculation is performed if required (S62 and S64).

After the second tapping of the melting furnaces 2, the molten metal material, the designated component target value, the tapping temperature and the like are verified, and repetition from the temperature adjustment of the melting furnaces 2 (S16) is performed. Sample collection (S18) and inspection are executed as required. For the processing ladle L1 on the receiving bogie 4, the molten metal material designated to receive or the component target value is compared with the measured value, and the aforementioned processes are repetitively executed. Likewise, also for the pouring ladle L2 on the conveyance bogie 6, the molten metal material or the component target value is compared with the measured value, and the aforementioned processes are repetitively executed.

The pouring ladle L2 are used in a circulated manner However, if the number of pouring ladles L2 is one, there is a possibility that the formed mold is made to wait for pouring from transfer to pouring. To prevent time loss due to waiting for pouring, a plurality of pouring ladles L2 can be used. Accordingly, when the empty ladle E is moved to the receiving position, pouring can be performed using the filled ladle F. Accordingly, a mold forming line is not required to be stopped when the empty ladle E is moved to the receiving position. As described above, except the period of movement of the filled ladle F from the ladle replacement device 7 to the pouring device 8, the state capable of pouring can be continued. Through use of a plurality of pouring ladles L2, molten metal being conveyed, and molten metal to be poured in actuality are in a state of being allowed to reside at the same time. According to the management system, by associating the ladle serial number, the furnace number with the furnace number and the number of tappings, and storing the associated items, the relationship between the original molten metal and the ladle can be managed even in such situations.

[Operation Example of Casting Facility]

FIGS. 16 and 17 show an example of the operation of the casting facility. FIG. 18 shows an example of information acquired from the casting facility. The operation of the casting facility is described with reference to FIGS. 16 and 17, while the information acquired from the casting facility using FIG. 18 is described.

FIG. 16(A) shows a scene where in a state of pouring by the pouring device 8, the conveyance bogie 6 stands by at the transfer position P4, and the receiving bogie 4 stands by at the primary inoculation position P1.

First, in the melting step, the melting materials are taken, and are injected by the melting material injection device 23 into the first melting furnace 21. The first melting furnace 21 starts melting, and adjusts the temperature of the original molten metal. Sample collection and inspection are performed as required (acquisition step). Based on the inspection result, the carbon adding amount is calculated, and carbon is further added.

Information acquired at this time is stored in the melting information management computer 101 in units of the furnace number and the number of tappings. As indicated by the field of “INSPECTION CHAMBER” in FIG. 18, information obtained in the inspection chamber (thermoanalysis result, elemental analysis result, carbon analysis result, and test piece inspection result) is associated with the furnace number and the number of tappings at the time point of completion of measurement, and is recorded in the melting information management computer 101. As indicated in the field of “MELTING FURNACE”, the type of the injected melting materials and the injection weight are recorded as the melting information in units of the furnace number and the number of tappings at the injection time point, in the melting information management computer 101 (melting management step).

The amount of lack of alloys is calculated from the component analysis of the original molten metal and the result of the wavefront inspection, and the pattern-specific component target value and molten metal material. Based on the calculated amount of lack of alloys, the alloys are measured and taken. The primary inoculation device 3 injects the measured alloys into the processing ladle L1 on the receiving bogie 4 standing by at the primary inoculation position P1. At the time point of injection or start of the receiving bogie 4, the ladle serial number is incremented and assigned to the processing ladle L1 (first assignment step). The assigned ladle serial number and the primary inoculation information are associated and stored (see the field of “PRIMARY INOCULATION DEVICE” in FIG. 18).

FIG. 16(B) shows a scene where in a state of pouring by the pouring device 8, the receiving bogie 4 into which the primary inoculation alloy materials have been injected is moved to the receiving position P2, and when preparation of the first melting furnace 21 is completed, the predetermined weight of original molten metal is received. At this receiving completion time point, the ladle serial number and the receiving information are associated and stored (see the field of “RECEIVING BOGIE” in FIG. 18). Since the receiving information is linked to the melting information, the furnace number and the number of tappings can be stored as the receiving information. Here, the ladle serial number is associated with the furnace number and the number of tappings (ladle management step). The tapping temperature, the tapping weight, tapping time and the like indicated in the field of “MELTING FURNACE” in FIG. 18 are collected at this time point, are associated with the furnace number and the number of tappings, and stored as the melting information.

FIG. 16(C) shows a scene where in a state of pouring by the pouring device 8, the receiving bogie 4 into which the primary inoculation alloy materials have been injected is moved to the receiving position P3, and when preparation of the second melting furnace 22 is completed, the predetermined weight of original molten metal is received. The information obtained this time is identical to that in FIG. 16(B). Note that only any one of FIGS. 16(B) and 16(C) is performed.

FIG. 17(A) shows a scene where in a state of pouring by the pouring device 8, the receiving bogie 4 having received the predetermined weight of the original molten metal reaches the transfer position P4, and the conveyance bogie 6 mounted with the empty pouring ladle L2 stands by at the transfer position P4. In a state where preparation of the receiving bogie 4 and the conveyance bogie 6 is completed, transfer from the processing ladle L1 on the receiving bogie 4 to the pouring ladle L2 on the conveyance bogie 6 is performed. Here, the secondary inoculation is performed by the secondary inoculation device 5. With preliminarily designated molten metal materials, the required amount of materials are taken by the alloy measurement device 52 from the secondary inoculation alloy hoppers 51 onto the conveyor belt 53. After start of the transfer, the materials are injected by the injection chute 54 into the transfer molten metal flow. According to completion of transfer, the ladle serial number is passed in order to cause the pouring ladle L2 on the conveyance bogie 6 through the ladle serial number to take over the information on the processing ladle L1 on the receiving bogie 4. The assigned ladle serial number and the primary inoculation information are associated and stored (see the field of “SECONDARY INOCULATION DEVICE” in FIG. 18).

FIG. 17(B) shows a scene where the pouring device 8 has completed pouring, the empty ladle E stands by at the empty ladle standby position P6 of the ladle replacement device 7, and the conveyance bogie 6 mounted with the filled ladle F has reached the ladle replacement position P5. At a time point of completion of pouring by the pouring device 8, the pouring information is stored in units of mold serial numbers (see the field “POURING DEVICE” in FIG. 18). To link the pouring information to the melting information, the ladle serial number is included in the pouring information. Accordingly, the mold serial number and the ladle serial number are associated with each other (pouring management step).

FIG. 17(C) shows a scene where the filled ladle F is mounted on the pouring device 8 by way of the filled ladle standby position P7 of the ladle replacement device 7, the pouring device 8 starts pouring, and the conveyance bogie 6 is mounted with the empty ladle E and returns it to the transfer position P4. As described above, since by using two or more pouring ladles, the time during which molten metal cannot be supplied to the pouring device 8 is reduced in comparison with a case of using one pouring ladle, pouring can be continuously performed without stopping the mold forming line.

FIGS. 16(A) to 17(C) are repetitively executed. Note that as indicated in the field of “MOLTEN METAL CONVEYANCE CONTROL PANEL” in FIG. 18, the molten metal conveyance control device main PLC 200 shifts the ladle serial number in conformity with the movement (position) of the ladle. Accordingly, the management system 10 can manage the information on pouring and thereafter in units of ladles.

[Example of Data Structure]

FIG. 19 shows an example of a data structure that the management system has. The melting information DB shown in FIG. 19 corresponds to the database 111 (furnace number and the-number-of-tappings reference DB) and the database 110 (furnace number and the-number-of-tappings reference DB) shown in FIG. 14. The ladle serial number DB shown in FIG. 19 corresponds to the database 110 (ladle serial number reference DB) shown in FIG. 14. The mold serial number DB shown in FIG. 19 corresponds to the database 110 (mold serial number reference DB) shown in FIG. 14. The test piece serial number DB is created based on the data acquired when the test piece is collected. The test piece serial number DB associates acquired data with the ladle serial number, and the associated items are managed in a unit of a ladle. An overall management information DB is a database that associates the ladle serial number, management information (the amount of discarded molten metal, and steel shell temperature of the ladle) with each other. A wire inoculation information DB is created when inoculation is performed with wire. The wire inoculation information DB also associates the acquired data with the ladle serial number, and the associated items are managed in a unit of a ladle.

As shown in FIG. 19, the melting information obtained in the melting step is collected and managed as a melting information DB, independent from the other steps. From receiving from the melting furnaces 2 to pouring, information is managed using the ladle serial number issued when the primary inoculation materials are injected into the ladle. The molten metal information is associated with the ladle serial number using the furnace number and the number of tappings. Accordingly, all the pieces of information are associated with each other, through the ladle serial number, the furnace number and the number of tappings. The pouring information is stored with reference to the mold serial number (issued when the mold is formed) of the mold into which pouring is performed. When required pieces of information are searched for from these pieces of information, a search is performed, with the furnace number and the number of tappings being adopted as search keys, or with the ladle serial number and the mold serial number being adopted as search keys.

[Modified Example 1 of Casting Facility]

FIG. 20 is a plan view showing another example of the

configuration of the casting facility. In comparison with the casting facility 1, a casting facility 1A shown in FIG. 20 is different in that the receiving bogie 4 passes the ladle having received the molten metal from the melting furnace 2, to the conveyance bogie 6, without transfer, but is the same in the other points. If the reaction between the molten metal and the alloy materials is not so active, reaction in the processing ladle L1 is not required, and the pouring ladle L2 can be caused to receive the molten metal and reaction is allowed. In comparison with the information processing in the casting facility 1, only taking over of the ladle number from the processing ladle L1 to the pouring ladle L2 is omitted, and the other points are the same. Accordingly, the management system 10 is applicable, as it is, also to the casting facility 1A.

[Modified Example 2 of Casting Facility]

FIG. 21 is a plan view showing another example of the configuration of the casting facility. In comparison with the casting facility 1, the casting facility 1B shown in FIG. 21 is different in that the receiving bogie 4 passes the ladle having received the molten metal from the melting furnace 2, to the conveyance bogie 6, without transfer, and in that instead of the primary inoculation device 3, a primary inoculation device 3A that inoculates the material with wire is adopted, but is the same in the other points. In comparison with the information processing in the casting facility 1, only taking over of the ladle number from the processing ladle L1 to the pouring ladle L2 is omitted, and the other points are the same. Accordingly, the management system 10 is applicable, as it is, also to the casting facility 1B. In a case where alloy materials and molten metal are reacted with wire inoculation, the position of wire inoculation serves as an injection position. Description of “when alloy materials are injected” may be read as “when wire inoculation is performed”.

[Modified Example 3 of Casting Facility]

FIG. 22 is a plan view showing another example of the configuration of the casting facility. In comparison with the casting facility 1, a casting facility 1C shown in FIG. 22 is different in that the number of pouring ladles L2 is three, and that a roller conveyor (standby position P8) for allowing the pouring ladles to stand by is added, but is the same in the other points. In comparison with the information processing in the casting facility 1, the point that management is performed in a unit of a ladle is not changed even if the numbers of pouring ladles L2 and movement positions increase. Accordingly, the management system 10 is applicable, as it is, also to the casting facility 1C.

As described above, according to the management system 10 and the management method, the melting information pertaining to the original molten metal is obtained for each of the melting furnaces 2. The melting information is associated with the furnace number and the number of tappings, in response to tapping of the original molten metal from one melting furnace 2 to the processing ladle L1, and is stored in the storage medium. Furthermore, the ladle serial number is associated with the furnace number and the number of tappings, in response to tapping of the original molten metal from one melting furnace 2 to the processing ladle L1, and is stored in the storage medium. The ladle serial number is associated with the mold serial number (an example of the identifier of the mold) at the time of pouring. As described above, the management system 10 can manage the melting information in a unit of a ladle, using the furnace number and the number of tappings. By associating the furnace number and the number of tappings with the ladle serial number, the management system 10 can associate, with the melting information, information on subsequent steps managed in a unit of a ladle, such as adjustment of the component of the original molten metal, conveyance, and pouring. Consequently, the management system 10 can manage information obtained from the melting step to the pouring step.

According to the management system 10, even if the ladle is transferred, the information obtained from the melting step to the pouring step can be managed. According to the management system 10, through the ladle serial number, and the furnace number and the number of tappings, the melting information can be associated with information on the first inoculation material. According to the management system 10, through the ladle serial number, and the furnace number and the number of tappings, the melting information can be associated with the information on the second inoculation material. According to the management system 10, since the ladle number and the ladle serial number are associated with each other, the pouring ladle can be uniquely identified. Accordingly, even in a case where a failure occurs in the ladle, the ladle causing the failure can be uniquely identified.

By managing the information obtained from the melting step to the pouring step, the cause of a fault product can be determined using much information (improvement in traceability). Furthermore, by acquiring much operation information, and by changing setting information based on previous information, a product having a higher quality can be manufactured (addition of a feedback function). For example, based on the previous-day information (graphite structure, inoculation amount, original molten metal compound ratio, resultant quality, etc.) acquired in the melting step, the melting materials on the current day is determined, which can improve the quality of the product. Furthermore, the safety can be improved using the collected information. For example, the alloy inoculation amount is compared with the weight measurement value of the receiving bogie, and if the difference is equal to or more than a predetermined value, a warning is issued, which can detect abnormality. The pouring device compares the materials included in the melting information with the materials acquired from the mold forming line, and in a case of a mismatch, a warning can be output and pouring can be stopped. If the time is significantly shorter or longer than a previous processing time or if the value is significantly less or more than a previous measurement value, a warning is output, which can detect abnormality. Alternatively, for example, the fading time is monitored, and if the predetermined time is exceeded, a warning indicating that spheroidization is not correctly achieved can be output. Alternatively, for example, the molten metal temperature is monitored, and if the temperature is equal to or less than the predetermined temperature, a warning may be output or the molten metal may be returned.

The management system 10 may cause a display device, such as a touch panel, to display various pieces of information. For example, the management system 10 may cause the display device of the pouring device 8 to display the materials fed from the mold forming line in units of frames, and the materials in the ladle sent from the furnace. Alternatively, the management system 10 may cause the display device of the pouring device 8 to display the pouring temperature, pouring time, pouring weight, taking time, fading time, elapsed time since the molten metal is received and the like. The management system 10 may cause the display device to display the information stored in the various DBs illustrated in FIG. 19.

The embodiments have thus been described above. However, this disclosure is not limited to the embodiments described above. For example, the volume of the processing ladle L1 is the same as that of the pouring ladle L2, however, there is no limitation thereto. For example, the volume of the processing ladle L1 may be twice as large as that of the pouring ladle L2. In this case, transfer may be performed from a single processing ladle L1 into two pouring ladles L2. The molten metal conveyance control device main PLC 200 may associate the ladle serial number with the furnace number and the number of melting times, and store the associated items in the storage medium. That is, instead of the furnace number and the number of tappings, the furnace number and the number of melting times may be used to manage and associate molten metal data.

REFERENCE SIGNS LIST

1 . . . Casting facility, 2 . . . Melting furnace, 3 . . . Primary inoculation device, 4 . . . Receiving bogie, 5 . . . Secondary inoculation device, 6 . . . Conveyance bogie, 7 . . . Ladle replacement device, 8 . . . Pouring device, 10 . . . Management system.

Claims

1. A management system for a casting facility tapping, into at least one ladle, a part of original molten metal obtained in one melting furnace among melting furnaces, adjusting a component of the original molten metal in the at least one ladle having received the original molten metal to obtain molten metal, conveying the at least one ladle retaining the molten metal to a pouring device, and pouring the molten metal in the conveyed at least one ladle into a mold using the pouring device, the management system comprising:

an acquisition unit configured to acquire melting information pertaining to the original molten metal for each of the melting furnaces;
a first assignment unit configured to assign a ladle serial number to the at least one ladle receiving the original molten metal;
a melting management unit configured to associate a furnace number identifying the one melting furnace, the number of tappings from the one melting furnace, and the melting information on the one melting furnace with each other, and storing associated items in a storage medium;
a ladle management unit configured to associate the ladle serial number, the furnace number, and the number of tappings with each other, in response to tapping of the original molten metal from the one melting furnace into the at least one ladle, and storing associated items in the storage medium; and
a pouring management unit configured to associate an identifier of the mold with the ladle serial number, in response to the pouring device pouring the molten metal in the conveyed at least one ladle into the mold, and storing associated items in the storage medium.

2. The management system according to claim 1,

wherein the at least one ladle includes a processing ladle receiving the original molten metal, and a plurality of pouring ladles receiving transferred contents from the processing ladle,
the casting facility transfers contents from the processing ladle into one pouring ladle among the pouring ladles, and
the management system further comprises a second assignment unit assigning the ladle serial number of the processing ladle to the one pouring ladle in response to transfer of the contents of the processing ladle into the one pouring ladle.

3. The management system according to claim 2, wherein the ladle management unit associates information on a first inoculation material injected into the processing ladle in order to adjust a component of the original molten metal, with the ladle serial number, and stores associated items in the storage medium.

4. The management system according to claim 2, wherein the ladle management unit associates information on a second inoculation material injected into the pouring ladle in order to adjust a component of molten metal, with the ladle serial number, and stores associated items in the storage medium.

5. The management system according to claim 2, wherein the ladle management unit associates an identifier identifying the pouring ladle with the ladle serial number, and stores associated items in the storage medium.

6. The management system according to claim 1, wherein the at least one ladle includes a plurality of ladles conveying molten metal to the pouring device.

7. A management method for a casting facility tapping, into at least one ladle, a part of original molten metal obtained in one melting furnace among melting furnaces, adjusting a component of the original molten metal in the at least one ladle having received the original molten metal to obtain molten metal, conveying the at least one ladle retaining the molten metal to a pouring device, and pouring the molten metal in the conveyed at least one ladle into a mold using the pouring device, the management system comprising:

an acquisition step of acquiring melting information pertaining to the original molten metal for each of the melting furnaces;
a first assignment step of assigning a ladle serial number to the at least one ladle receiving the original molten metal;
a melting management step of associating a furnace number identifying the one melting furnace, the number of tappings from the one melting furnace, and the melting information on the one melting furnace with each other, and storing associated items in a storage medium;
a ladle management step of associating the ladle serial number, the furnace number, and the number of tappings with each other, in response to tapping of the original molten metal from the one melting furnace into the at least one ladle, and storing associated items in the storage medium; and
a pouring management step of associating an identifier of the mold with the ladle serial number, in response to the pouring device pouring the molten metal in the conveyed at least one ladle into the mold, and storing associated items in the storage medium.

8. The management system according to claim 3, wherein the ladle management unit associates information on a second inoculation material injected into the pouring ladle in order to adjust a component of molten metal, with the ladle serial number, and stores associated items in the storage medium.

9. The management system according to claim 3, wherein the ladle management unit associates an identifier identifying the pouring ladle with the ladle serial number, and stores associated items in the storage medium.

10. The management system according to claim 4, wherein the ladle management unit associates an identifier identifying the pouring ladle with the ladle serial number, and stores associated items in the storage medium.

11. The management system according to claim 2, wherein the at least one ladle includes a plurality of ladles conveying molten metal to the pouring device.

12. The management system according to claim 3, wherein the at least one ladle includes a plurality of ladles conveying molten metal to the pouring device.

13. The management system according to claim 4, wherein the at least one ladle includes a plurality of ladles conveying molten metal to the pouring device.

14. The management system according to claim 5, wherein the at least one ladle includes a plurality of ladles conveying molten metal to the pouring device.

Patent History
Publication number: 20210213522
Type: Application
Filed: Apr 26, 2019
Publication Date: Jul 15, 2021
Applicants: SINTOKOGIO, LTD. (Nagoya-shi, Aichi), Fujiwa Denki Co., Ltd. (Nagoya-shi, Aichi)
Inventors: Tadashi NISHIDA (Nagoya-shi, Aichi), Toshiyuki HYODO (Nagoya-shi, Aichi), Masanori HOSHINO (Nagoya-shi, Aichi)
Application Number: 17/057,997
Classifications
International Classification: B22D 41/12 (20060101); B22D 46/00 (20060101); B22D 47/02 (20060101); B22D 41/06 (20060101);