Casting of Compressor Housing Manufacturers

How automated is a compressor casing casting manufacturer's compressor casing casting production line?

1. Application of automation technology
Intelligent flexible production line: A high degree of automation has been achieved during the assembly and welding process of compressor housing components. For example, the intelligent flexible production line for compressor housing components successfully developed by the 724th Institute of Pengli Intelligent Equipment Company can complete fully intelligent welding of multiple components of the compressor, significantly improving the welding qualification rate and production efficiency, while reducing manpower Cost (75% headcount reduction). The application of this technology not only improves product quality, but also makes production more efficient, flexible and green.
Intermediate frequency power supply resistance welding process: In the automated production line of the refrigerator compressor lower casing, Henglong's intermediate frequency power supply is used to realize the resistance welding process of copper tubes and steel shells. This technology is not only energy-saving and environmentally friendly, but also ensures the welding quality. Quality stability and reliability (Source: Refrigerator compressor lower shell automated production line).
2. Integration of digitalization and intelligence
Digital Intelligent Foundry: Yantai Binglun Intelligent Machinery Technology Co., Ltd. invested in the construction of a full-process digital intelligent foundry. Through the application of Internet of Things technology, the equipment numerical control rate and equipment networking rate were both 100%. The factory realizes automated operation of the entire process from 3D printing sand cores to casting molding, which greatly improves production efficiency and product quality, and also promotes the green and intelligent transformation of the foundry industry.
Intelligent monitoring and data analysis: The intelligent casting factory is equipped with cameras, intelligent operating terminals, etc. integrated in the intelligent control center, which can remotely monitor the operation of each equipment and collect various production data through sensors, including product qualification rate, equipment quality Operating rate, etc., provide strong data support for the company's production management and decision-making.
The compressor casing casting production line has a very high degree of automation. It not only realizes the automation of multiple production links, but also improves production efficiency and product quality through digital and intelligent means. With the continuous advancement of technology and the deepening of its application, the degree of automation of the compressor casing casting production line is expected to be further improved.

How can compressor housing casting suppliers control and reduce common defects in the compressor housing casting process through process optimization and technical means?
In the compressor housing casting process, common defects include hot cracks, cold cracks, cold shuts, sand holes, pores, shrinkage cavities and shrinkage. These defects not only affect the quality and performance of the castings, but may also cause the castings to be scrapped and increase production costs. The following are specific methods to control and reduce these defects through process optimization and technical means:
1. Control of hot cracks and cold cracks
Optimize mold design:
Ensure that the mold structure is reasonable to avoid excessive internal stress in the casting during cooling.
Use appropriate fillet size to make the uneven wall thickness of the casting transition evenly.
Control pouring temperature:
Lower the pouring temperature to reduce the thermal stress of the casting during solidification.
For metal mold casting, pay special attention to the working temperature of the mold to avoid too fast cooling.
Improve coating performance:
Choose a coating with good air permeability and spray it evenly to avoid too thin or too thick coating layer.
The coating should have good thermal insulation and heat insulation properties to slow down the cooling rate of the casting.
Optimize the pouring system:
Reasonably design the pouring system to ensure that the molten metal flows into the cavity smoothly and evenly.
Appropriately increase the number and volume of risers to improve the shrinkage compensation capacity of the casting.
2. Control of cold shut
Increase the pouring speed:
Appropriately increase the pouring speed so that the molten metal can fill the cavity faster and reduce the occurrence of cold shut.
Optimize the exhaust system:
Ensure that the mold exhaust system is unobstructed so that the gas can be discharged in time.
Use the inclined pouring method to help the gas float and escape.
Improve the quality of the coating:
Use good quality coating to avoid the coating from generating gas during the pouring process.
3. Control of sand holes
Improve the quality of the sand core:
Ensure that the surface of the sand core is smooth, strong, and free of burns or incomplete solidification.
The size of the sand core should match the outer mold to avoid crushing the sand core when closing the mold.
Optimize the pouring operation:
Avoid friction between the ladle and the sand core to prevent sand particles from falling into the cavity.
Clean the surface of the mold cavity before pouring to ensure that there is no sand residue.
4. Control of pores
Strictly control the quality of raw materials:
Ensure that the charge is dry, clean, and free of rust and oil.
Raw materials should be stored in a ventilated and dry place and preheated before use.
Improve the air permeability of the mold:
The surface of the mold cavity should be free of defects such as holes and pits to ensure that the gas can be discharged smoothly.
Use coatings and molding sand with good air permeability.
Optimize the pouring process:
Appropriately increase the pouring temperature to allow the gas to have enough time to float and escape.
Avoid eddy currents and splashes in the molten metal during pouring to reduce gas entrapment.
5. Control of shrinkage and shrinkage
Control the composition of molten iron:
Adjust the composition of molten iron to keep the carbon and silicon content within the specified range and reduce the shrinkage tendency.
Optimize the pouring temperature and speed:
Appropriately reduce the pouring temperature and speed to reduce liquid shrinkage and solidification shrinkage.
Strengthen the design of risers:
Increase the volume and number of risers to ensure that the risers can fully compensate for shrinkage.
Optimize the position and design of risers to achieve the best shrinkage compensation effect.
Improve mold insulation performance:
Partially heat the mold or use insulation materials to partially insulate it to slow down the cooling rate of the casting.
Through the above process optimization and technical means, common defects in the compressor housing casting process can be effectively controlled and reduced, and the quality and performance of the casting can be improved. At the same time, it is also necessary to strengthen quality control and testing in the production process, timely discover and deal with defects, and ensure that the casting meets the design requirements.