Automatic dip-coating and drying method for sand core

Abstract

The invention discloses an automatic dip-coating and drying method for a sand core, and relates to the technical field of sand core casting. The method is applied to a core making system comprising a mechanical arm, a sand core is clamped through the mechanical arm and moved to a coating pool, and the mechanical arm is controlled to move so that the sand core can reach the preset dip-coating depth; lifting the mechanical arm to a preset height, and driving the mechanical arm to swing based on a preset swing strategy so as to prevent the coating on the surface of the sand core from continuously dripping; the swung sand core is moved to a drying furnace, and drying adsorption of coating on the surface of the sand core is achieved based on a preset drying strategy; and the deformation amount of the dried sand core is detected and compared with a preset deformation amount threshold value, and whether the sand core is qualified or not is judged according to the comparison result. Accurate control and optimization of the sand core manufacturing process are achieved, and the manufacturing quality and production efficiency of the sand core are remarkably improved.

Description

Technical Field

[0001] The invention relates to the technical field of sand core casting, in particular to an automatic dipping and drying method for a sand core. Background Art

[0002] In the casting field, the quality of sand cores, as key components for forming the internal structure of castings, directly affects the accuracy and performance of the final castings. In the traditional sand core manufacturing process, manual operations dominate, especially in the two key steps of dipping and drying the sand cores. Manual dipping can easily cause uneven coating, affecting the subsequent casting quality; and the drying process often relies on natural air drying or simple hot air equipment, which cannot accurately control the temperature and time, resulting in deformation, cracking and other problems of the sand core. In addition, the lack of automated monitoring means makes it difficult to detect and correct quality problems at an early stage. Defects are often not discovered until the end of the casting process or even later, greatly increasing production costs and cycles.

[0003] In recent years, although some automated equipment has been introduced into sand core manufacturing, these systems are usually relatively simple and only automate a certain part of the operation, failing to form a complete closed-loop control. In view of this, an automatic dipping and drying method for sand cores is now provided. Summary of the invention

[0004] The present invention provides an automatic dipping and drying method for sand cores. Through highly integrated automation and intelligent technology, it not only realizes the precise control and optimization of the sand core manufacturing process, but also forms a complete closed-loop control from production execution to quality monitoring to parameter feedback adjustment, which significantly improves the manufacturing quality and production efficiency of the sand cores.

[0005] In order to achieve the above object, the present invention provides an automatic dipping and drying method for sand cores, which is applied to a core making system including a robotic arm, and comprises:

[0006] The sand core is clamped by the mechanical arm and moved to the coating pool, and the movement of the mechanical arm is controlled so that the sand core reaches a preset immersion depth;

[0007] The mechanical arm is lifted to a preset height, and driven to swing based on a preset swing strategy to prevent the coating on the surface of the sand core from continuously dripping;

[0008] The swung sand core is moved to a drying furnace to achieve dry adsorption of the coating on the surface of the sand core based on a preset drying strategy;

[0009] The deformation amount of the sand core after drying is detected and compared with a preset deformation amount threshold, and whether the sand core is qualified is determined according to the comparison result.

[0010] Preferably, the sand core is clamped by the mechanical arm, specifically:

[0011] When the transfer tray in the core making system is transferred to the dipping station via the transfer roller line, a visual sensor is used to determine whether the sand core is in the transfer tray;

[0012] If it is determined that the sand core exists, the transfer tray is stopped and positioned, and the mechanical arm is controlled by the visual sensor to move and clamp the sand core. After the mechanical arm clamps, the transfer tray is released to enter a circular transfer;

[0013] If it is determined that the sand core does not exist, the transfer tray is allowed to avoid the stop position and circulate normally.

[0014] Preferably, the visual sensor is used to control the robot arm to move and clamp the sand core, specifically:

[0015] Controlling the robot arm to move to the grabbing position of the sand core through the visual sensor, and determining whether the position of the sand core is the same as the preset position;

[0016] If the position of the sand core is the same as the preset position, controlling the clamp of the robot arm to clamp the sand core;

[0017] If the sand core position is different from the preset position, the robot arm is controlled to reset to the initial position and an alarm message is issued.

[0018] Preferably, the sand core is moved to the coating pool, and the movement of the robot arm is controlled so that the sand core reaches a preset immersion depth, specifically:

[0019] The mechanical arm clamps the sand core and moves it into the coating pool, and measures the distance between the mechanical arm clamp and the liquid surface of the coating pool by a distance measuring sensor;

[0020] When the distance is shortened to a preset distance, the robot arm is controlled to stop descending, so that the sand core reaches a preset immersion depth.

[0021] Preferably, the mechanical arm is lifted to a preset height, and driven to swing based on a preset swing strategy, specifically:

[0022] After the mechanical arm clamps the dip-coated sand core and vertically lifts it to a preset height, the mechanical arm is driven to swing based on a preset swing strategy to reduce excess coating on the surface of the sand core;

[0023] The preset swing strategy is to control the robot arm to tilt in the left and right directions at preset angles in turn and return to the center after staying for a preset time.

[0024] Preferably, the sand core after dip coating is moved to a drying furnace, and the dry adsorption of the coating on the surface of the sand core is achieved based on a preset drying strategy, specifically:

[0025] The robot arm places the sand core after dipping on a drying tray of a drying roller line in the core making system, and the drying tray carries the sand core through the drying roller line through a drying furnace;

[0026] The preset temperature and the preset wind speed of the drying furnace are adjusted based on the preset drying strategy, and the surface coating of the sand core is dried by the drying furnace.

[0027] Preferably, the deformation amount of the sand core after drying is detected and compared with a preset deformation amount threshold, and whether the sand core is qualified is judged according to the comparison result, specifically:

[0028] After the sand core is dried out of the furnace, its deformation is detected by scanning with a laser sensor, and the deformation is compared with a preset deformation threshold;

[0029] If the deformation is less than or equal to , the sand core is judged to be qualified;

[0030] If the deformation is greater than, the sand core is judged to be unqualified.

[0031] Preferably, it also includes:

[0032] When the sand core is judged to be qualified, the mechanical arm is controlled to clamp the sand core for core assembly;

[0033] When it is determined that the sand core is unqualified, the robot arm is controlled to place the sand core in an area to be evaluated, and at the same time, the detection data of the laser sensor is sent to a data platform and an alarm is issued.

[0034] Preferably, the detection data of the laser sensor is sent to a data platform, specifically:

[0035] After the detection data of the laser sensor is sent to the data platform, the core making equipment automatically adjusts the addition amount parameters of each additive based on the detection data through a preset addition strategy to achieve quality optimization of the sand core.

[0036] Preferably, the addition amount parameters of each additive are automatically adjusted by a preset addition strategy, specifically:

[0037] The amount of resin added is increased in steps of 0.1 wt% / time. When the amount of resin added reaches the preset upper limit of 1.1 wt%, the amount of anti-veining agent added is decreased in steps of 0.1 wt% / time.

[0038] The embodiment of the present application discloses a method for automatic dipping and drying of sand cores. This method realizes a fully automated process of sand core grabbing, dipping, swinging to remove excess materials and drying through the precise operation of a robotic arm, significantly improving production efficiency; using high-precision sensing equipment such as visual sensors and range-finding sensors to ensure accurate positioning and processing of sand cores in each link, combined with a preset dipping depth and a preset swinging strategy, improves the uniformity of the coating and the accuracy of thickness control; by real-time monitoring of the deformation of the sand core after drying and comparing it with the preset standard, an immediate quality assessment is achieved, unqualified products can be quickly identified and isolated, avoiding waste of resources for further processing, and providing a basis for the dynamic adjustment of process parameters through this immediate feedback mechanism, promoting production Continuous improvement of the production process; combined with the detection data of the laser sensor, the amount of each additive is automatically adjusted through the preset addition strategy, realizing the intelligent optimization of the sand core quality, effectively reducing the quality problems caused by improper additive ratio, and improving the stability and reliability of the sand core; the automated dipping and drying process reduces the excessive use and waste of coatings, and at the same time reduces energy consumption by precisely controlling the drying conditions, meeting the requirements of modern green manufacturing; by integrating advanced automation technology, precision sensing technology and intelligent control strategies, not only the automation level and production efficiency of sand core manufacturing are improved, but also the accuracy of product quality control and the effectiveness of the feedback mechanism are significantly enhanced. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solution of the present application, the drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0040] Figure 1 It is a schematic diagram of a process of automatic dipping and drying method of a sand core;

[0041] Figure 2 This is a flowchart of a specific embodiment of the present application. DETAILED DESCRIPTION

[0042] As described in the background technology, in the traditional sand core manufacturing process, manual dipping is prone to uneven coating, affecting the subsequent casting quality; and the drying process often relies on natural air drying or simple hot air equipment, which cannot accurately control the temperature and time, resulting in deformation, cracking and other problems of the sand core. In addition, the lack of automated monitoring means makes it difficult to detect and correct quality problems at an early stage, greatly increasing production costs and cycles. In recent years, although some automated equipment has been introduced into sand core manufacturing, these systems are usually relatively simple and only automate a certain part of the operation, failing to form a complete closed-loop control.

[0043] In order to solve the above problems, the embodiment of the present application proposes an automatic dipping and drying method for sand cores. Through highly integrated automation and intelligent technology, not only the precise control and optimization of the sand core manufacturing process is achieved, but also a complete closed-loop control from production execution to quality monitoring to parameter feedback adjustment is formed, which significantly improves the manufacturing quality and production efficiency of the sand cores.

[0044] like Figure 1 FIG. 1 is a flow chart of the automatic dipping and drying method of the sand core. Specifically, the method comprises the following steps:

[0045] Step S101, clamping the sand core by the robot arm, and moving the sand core to the coating pool, and controlling the movement of the robot arm to make the sand core reach a preset immersion depth.

[0046] As mentioned above, the free end of the robot arm is provided with a clamp, which can accurately perform the clamping action according to the preset program, ensure a gentle and firm grip on the sand core, and avoid damage or deformation of the sand core during handling. The sand core is driven to move to the coating pool by the robot arm. Based on the shape, size and material characteristics of the sand core, the ideal dipping depth is pre-set by the control system, and the movement of the robot arm is controlled in combination with the distance sensor to achieve reasonable dipping of the coating on the surface of the sand core.

[0047] For example, suppose in a specific embodiment, a cylindrical sand core with a diameter of 10 cm and a length of 20 cm needs to be dip-coated. First, the computer-aided design (CAD) software is used to simulate and calculate that the optimal dip-coating depth is 1 / 3 of the sand core diameter, that is, about 3.3 cm, to ensure that the coating is uniform and of moderate thickness. After receiving the instruction, the robot arm accurately clamps the sand core and slowly lowers it into the coating pool. At the same time, the ranging sensor continuously feeds back data. When it reaches the preset depth of 3.3 cm, the robot arm immediately stops descending, maintains this depth for a period of time to ensure that the coating is fully penetrated, and then rises steadily to complete the dip-coating process.

[0048] It should be noted that adaptive dipping depth adjustment schemes, such as the system automatically fine-tuning the preset dipping depth through an algorithm according to the different sand core materials (such as sand grain size, binder type, etc.) to achieve more refined control; intelligent coating quality monitoring schemes, such as during the dipping process, using a camera installed on a robotic arm to take real-time photos of the sand core surface, using image recognition technology to analyze the uniformity and integrity of the coating, and immediately feeding back to the control system if any abnormality is found, for immediate adjustment or re-dipping, all fall within the scope of protection of this application.

[0049] Step S102: lift the robot arm to a preset height, and drive the robot arm to swing based on a preset swing strategy to prevent the coating on the surface of the sand core from continuously dripping.

[0050] As mentioned above, based on the size and shape of the sand core, the corresponding lifting height is pre-set by the control system. After the dipping is completed, the robot arm clamps the sand core and lifts it to the preset height to prevent the sand core from contacting the liquid surface of the coating pool when the robot arm swings. Subsequently, the robot arm swings cyclically according to the preset swing strategy. The swing strategy is used to change the direction of gravity to cause the excess coating on the surface of the sand core to slide off, so as to prevent the continuous dripping of the coating on the surface of the sand core, achieve uniform adhesion of the coating on the surface of the sand core, and avoid damage to the already applied coating.

[0051] For example, suppose the sand core is an elongated cylinder with a diameter of 5 cm and a height of 20 cm. After the dipping is completed, the robot arm will lift the sand core to a height of about 30 cm from the surface of the paint pool to allow most of the excess paint to drip naturally due to gravity, ensuring uniform adhesion of the paint on the surface of the sand core. At this time, the preset swing strategy is: first tilt 15 degrees to the left and hold for 3 seconds, then slowly return to the right, then tilt 15 degrees to the right and hold for 3 seconds, then return to the right, and repeat this twice. This gentle and regular swinging action helps to cause excess paint on the surface of the sand core to slide off, achieve uniform distribution of the paint, and avoid damage to the already applied coating.

[0052] It should be noted that intelligent drip detection and dynamic adjustment solutions, such as integrated sensors (such as infrared or weight sensors) to monitor paint dripping in real time while the robotic arm is swinging. If the sensor detects that the amount of paint dripping exceeds expectations, the system will automatically adjust the swing amplitude, frequency or duration to more effectively remove excess paint while reducing energy consumption; adaptive swing strategy optimization solutions, such as through machine learning algorithms, automatically optimize the swing strategy according to factors such as the different sizes and shapes of sand cores and paint characteristics. The system collects data after multiple operations and learns the most efficient swing mode to automatically select the optimal solution when facing similar tasks in the future, thereby improving work efficiency and coating quality; environmentally friendly energy-saving mode solutions, such as during non-peak production periods or when the requirements for paint dripping control are not high, the system can switch to energy-saving mode, adopt a simplified swing strategy or reduce the swing frequency, thereby saving energy and reducing noise, while maintaining a sufficient level of coating quality control, all of which fall within the scope of protection of this application.

[0053] Step S103: moving the swung sand core to a drying furnace, and achieving dry adsorption of the coating on the surface of the sand core based on a preset drying strategy.

[0054] As described above, the robot arm holds the sand core after multi-material removal through the fixture at the free end, and accurately moves the sand core into the drying oven, and applies the preset drying strategy to ensure that the coating is evenly and thoroughly dried and firmly adsorbed on the surface of the sand core. This process includes but is not limited to: the robot arm accurately controls the sand core to be placed on a specific bracket or conveyor belt of the drying oven, and then starts the drying program based on the preset drying strategy. The preset drying strategy is customized according to the sand core material, coating type and the optimal drying conditions required (such as temperature, wind speed, time) to achieve the best drying effect and avoid cracking, peeling of the coating or deformation of the sand core.

[0055] For example, assume that the sand core is a small complex geometry with a layer of fast-curing epoxy resin coating on the surface. The robot arm gently places the sand core on a high-temperature resistant stainless steel grid in the drying oven, which is designed with good air circulation to promote uniform drying. The drying oven is started according to the preset drying strategy, with a set temperature of 60°C and a wind speed of 5 meters per minute for 30 minutes, which is designed to accelerate the curing process of the resin while ensuring uniform heat distribution to avoid local overheating that may cause coating defects or damage to the sand core structure.

[0056] It should be noted that intelligent temperature and humidity control and feedback adjustment solutions, such as introducing environmental sensors to monitor the actual temperature and humidity in the drying furnace, and comparing them with the preset ideal drying curve in real time, automatically adjusting the output of the heating element and the ventilation system through the PID controller to maintain the optimal drying environment and ensure the consistency of the coating between different batches; multi-mode drying strategy selection solutions, such as according to the specific needs of the sand core, the system provides a variety of drying modes to choose from, such as the fast drying mode is suitable for emergency orders, the energy-saving mode is used during non-peak hours to save energy, and the low-temperature long-time mode is suitable for special temperature-sensitive coatings to protect the integrity of the sand core structure; online monitoring and quality prediction solutions for drying effects, such as integrated infrared imaging or near-infrared spectrometers, real-time monitoring of physical changes in the coating drying process (such as moisture content, degree of curing), combined with data analysis models to predict the drying end point and coating quality, early warning of possible insufficient or excessive drying, reduce the production of defective products, and improve the yield rate, all belong to the protection scope of this application.

[0057] Step S104: detecting the deformation of the sand core after drying, and comparing it with a preset deformation threshold, and judging whether the sand core is qualified according to the comparison result.

[0058] As mentioned above, the deformation of the sand core after drying is accurately detected and compared with the preset standard threshold to determine whether the sand core meets the quality requirements in a scientific and objective way. This process includes the use of high-precision testing equipment, such as laser scanners or 3D profilometers, to perform a full-scale scan of the size and shape of the sand core to obtain accurate deformation data. The system then compares this data with the preset allowable deformation range. If the deformation does not exceed the threshold, the sand core is judged to be qualified. Otherwise, it is unqualified and needs to be further processed or discarded.

[0059] For example, large and complex sand cores used in casting automobile engine blocks are fully scanned with a resolution of one square millimeter after drying using non-contact laser scanning technology to record their three-dimensional geometric shape. The preset deformation threshold is ±0.5mm in the length direction and ±0.3mm in the width and height directions. After system analysis, if the maximum deformation of the sand core is 0.4mm in the length direction and does not exceed 0.2mm in the width and height directions, both of which are within the allowable range, the sand core is judged to have passed the quality inspection and is suitable for subsequent casting.

[0060] It should be noted that the real-time deformation correction and feedback adjustment scheme, such as when it is detected that the deformation of the sand core exceeds the preset threshold, the system can not only immediately judge it as unqualified, but also try to correct the deformation through subsequent fine-tuning processing (such as local heating, cooling or mechanical compression), and at the same time feed back this deformation data to the previous dipping and drying process, automatically adjust the relevant parameters, and prevent similar problems from occurring in future batches; the multi-dimensional quality evaluation system scheme, such as in addition to the deformation, further integrating the detection of other quality indicators, such as coating thickness, density uniformity, etc., to build a comprehensive quality evaluation system, so that even if the deformation of the sand core is qualified, but other indicators do not meet the requirements, they can be discovered and handled in time to ensure that the comprehensive performance of the sand core meets the standards; intelligent prediction and preventive maintenance schemes, such as using big data analysis and machine learning algorithms to predict the trend of sand core deformation based on historical detection data, adjust process parameters or maintenance equipment in advance, avoid potential deformation problems, and optimize the production process by analyzing the relationship between deformation and various process parameters, and improve the stability and efficiency of the overall manufacturing, all belong to the protection scope of this application.

[0061] In order to more intelligently and efficiently carry out automatic grabbing of the sand core by the robot arm, the sand core is clamped by the robot arm as follows:

[0062] When the transfer tray in the core making system is transferred to the dipping station via the transfer roller line, a visual sensor is used to determine whether the sand core is in the transfer tray;

[0063] If it is determined that the sand core exists, the transfer tray is stopped and positioned, and the mechanical arm is controlled by the visual sensor to move and clamp the sand core. After the mechanical arm clamps, the transfer tray is released to enter a circular transfer;

[0064] If it is determined that the sand core does not exist, the transfer tray is allowed to avoid the stop position and circulate normally.

[0065] As mentioned above, the transfer pallet carries the sand core along the transfer roller to the dipping area. At this time, the visual sensor intervenes and checks whether there is a sand core on the transfer pallet through the visual sensor. After confirming the existence of the sand core, the system pauses the pallet and aligns it accurately. Then the visual sensor guides the robot arm to move accurately above the sand core and clamp the sand core safely through the clamp. After the clamp is successfully clamped, the pallet is unpaused and returns to the circulation transportation process. If the sensor detects that there is no sand core, the pallet continues its circulation path directly without stopping. This optimization combines the collaborative operation of visual inspection and the robot arm to ensure the efficient operation of the process and the rational allocation of resources.

[0066] In order to ensure the accuracy of sand core grabbing and the reliability of system operation, the visual sensor is used to control the robot arm to move and clamp the sand core, specifically:

[0067] Controlling the robot arm to move to the grabbing position of the sand core through the visual sensor, and determining whether the position of the sand core is the same as the preset position;

[0068] If the position of the sand core is the same as the preset position, controlling the clamp of the robot arm to clamp the sand core;

[0069] If the sand core position is different from the preset position, the robot arm is controlled to reset to the initial position and an alarm message is issued.

[0070] As mentioned above, in the optimized automatic grasping process, the visual sensor first accurately locates the actual position of the sand core on the transfer pallet, and then the system compares and verifies this position with the preset ideal grasping position. When it is confirmed that the position of the sand core matches the preset position, the control system will command the robot arm to move to the position accurately according to the guidance of the visual sensor, and start the clamp to smoothly grasp the sand core; once a position deviation is found, the robot arm will be instructed to return to the initial safe position and immediately trigger an alarm notification to avoid erroneous operations and ensure the accuracy and safety of the operation. The whole process reflects the efficient integration of precise control of automated operations and abnormal management.

[0071] In order to improve the quality and efficiency of sand core coating, the sand core is moved to the coating pool, and the movement of the robot arm is controlled so that the sand core reaches a preset immersion depth, specifically:

[0072] The mechanical arm clamps the sand core and moves it into the coating pool, and measures the distance between the mechanical arm clamp and the liquid surface of the coating pool by a distance measuring sensor;

[0073] When the distance is shortened to a preset distance, the robot arm is controlled to stop descending, so that the sand core reaches a preset immersion depth.

[0074] As mentioned above, the robot arm holds the sand core and gradually descends and enters the coating pool. During this process, the vertical distance from the bottom of the fixture to the coating liquid surface is continuously monitored by the distance sensor installed on the robot arm. The preset dipping depth is calculated and set in advance according to the sand core characteristics and coating requirements. Once the sensor detects that the current distance is equal to the preset dipping depth value, the control system responds immediately and instructs the robot arm to suspend the diving action to ensure that the depth of the sand core immersed in the coating is just right, neither too shallow to affect the uniformity of the coating, nor too deep to cause the coating to clog the pores and waste, thereby optimizing resource utilization while ensuring the coating quality and efficiency.

[0075] In order to ensure the uniformity and quality of the coating, the robotic arm is raised to a preset height and driven to swing based on a preset swing strategy, specifically:

[0076] After the mechanical arm clamps the dip-coated sand core and vertically lifts it to a preset height, the mechanical arm is driven to swing based on a preset swing strategy to reduce excess coating on the surface of the sand core;

[0077] The preset swing strategy is to control the robot arm to tilt in the left and right directions at preset angles in turn and return to the center after staying for a preset time.

[0078] As mentioned above, first, the robot arm clamps the dip-coated sand core and lifts it vertically to a preset height. This height setting is designed to ensure that the excess paint on the surface of the sand core can be effectively detached during the subsequent swinging process without affecting the sand core structure or the applied coating due to excessive swinging. Then, according to the preset swinging strategy, the robot arm begins to swing in an orderly manner - the specific strategy is: the robot arm first tilts to the left at a preset angle and pauses at this position for a preset time to allow the excess paint loosened by gravity to slide naturally; then, the robot arm returns to a vertical state and tilts to the right again at the same angle, and stays for the same time to ensure that the excess paint is effectively removed. Repeat this left and right swinging action until the preset number of times is reached or the effect meets the requirements, and finally the robot arm returns to the right position to complete the entire process of removing excess paint, achieving efficient and gentle reduction of excess paint on the surface of the sand core.

[0079] In order to improve the quality and efficiency of drying, the sand core after dip coating is moved to a drying furnace, and the dry adsorption of the coating on the surface of the sand core is achieved based on a preset drying strategy, specifically:

[0080] The robot arm places the sand core after dipping on a drying tray of a drying roller line in the core making system, and the drying tray carries the sand core through the drying roller line through a drying furnace;

[0081] The preset temperature and the preset wind speed of the drying furnace are adjusted based on the preset drying strategy, and the surface coating of the sand core is dried by the drying furnace.

[0082] As mentioned above, the robotic arm places the sand core on the drying tray in the core making system. The drying tray equipped with the sand core is sent into the drying furnace and smoothly passes through the furnace under the guidance of the drying roller line to achieve the drying and curing of the coating. The drying process strictly follows the preset drying strategy, which is pre-set according to factors such as the sand core material and coating characteristics to ensure the drying effect. Specifically, the temperature and wind speed in the drying furnace are automatically adjusted according to the strategy to create the most suitable drying environment. The appropriate temperature accelerates the evaporation of the paint moisture, while the carefully controlled wind speed promotes air circulation and helps the surface coating to dry evenly, while avoiding coating defects such as cracking and peeling that may be caused by local overheating or uneven drying. Through such precise control, not only the drying efficiency is improved, but also the perfect adsorption and molding of the coating on the surface of the sand core is ensured.

[0083] In order to timely discover the deformation quality problem of the sand core, the deformation amount of the sand core after drying is detected and compared with the preset deformation threshold value, and whether the sand core is qualified is judged according to the comparison result, specifically:

[0084] After the sand core is dried out of the furnace, its deformation is detected by scanning with a laser sensor, and the deformation is compared with a preset deformation threshold;

[0085] If the deformation is less than or equal to , the sand core is judged to be qualified;

[0086] If the deformation is greater than, the sand core is judged to be unqualified.

[0087] As mentioned above, after the sand core is fully dried and removed from the furnace, it is immediately scanned comprehensively using a high-precision laser sensor. This scanning process can accurately capture the subtle morphological changes of the sand core and quantify the actual deformation. The system then automatically compares and analyzes the measured deformation value with the pre-set deformation threshold. If the detected deformation value does not exceed the preset allowable range, that is, the deformation is less than or equal to the threshold, the system will determine that the sand core meets the quality standards in terms of deformation and mark it as a qualified product. On the contrary, if the deformation exceeds the preset threshold, it means that the sand core is deformed too much and does not meet the production requirements. The system will accordingly determine that the sand core is a defective product. This immediate detection and judgment process ensures that only sand cores with stable morphology and up-to-standard quality enter the subsequent production process, effectively improving the overall quality and production efficiency of casting products.

[0088] In order to ensure and improve the quality of sand cores, it also includes:

[0089] When the sand core is judged to be qualified, the mechanical arm is controlled to clamp the sand core for core assembly;

[0090] When it is determined that the sand core is unqualified, the robot arm is controlled to place the sand core in an area to be evaluated, and at the same time, the detection data of the laser sensor is sent to a data platform and an alarm is issued.

[0091] As mentioned above, once the system determines that the deformation of the sand core after drying is qualified, it means that it meets the standard for continued processing. At this time, the robot arm will automatically execute the next process, that is, accurately clamp the qualified sand core and transport it to the next station for core assembly, ensuring the seamless connection and efficiency of the production process. On the contrary, if the test results show that the deformation of the sand core exceeds the standard and is considered to be unqualified, the robot arm will follow another set of preset instructions to safely place the unqualified sand core in a specific area to be evaluated. At the same time, the test data collected by all laser sensors related to the unqualified judgment will be transmitted to the central data platform in real time. This move is intended to summarize and analyze the information of defective products and provide data support for subsequent process improvements and quality control. In addition, the system will also trigger an alarm signal to promptly notify relevant personnel to pay attention to the handling and review of unqualified sand cores to prevent defective products from flowing into the next process and ensure strict control of product quality.

[0092] In order to achieve a continuous optimization cycle of sand core quality, the detection data of the laser sensor is sent to the data platform, specifically:

[0093] After the detection data of the laser sensor is sent to the data platform, the core making equipment automatically adjusts the addition amount parameters of each additive based on the detection data through a preset addition strategy to achieve quality optimization of the sand core.

[0094] As mentioned above, first, the detailed data obtained by the laser sensor after the detection is completed will be transmitted to the central data platform in real time. This data platform acts as a hub for information aggregation and analysis. It receives and processes real-time data from various sensors. Then, based on these accurate detection results, the control system of the core-making equipment will automatically activate the preset strategy algorithm, which can intelligently analyze the possible factors causing deformation according to the specific situation of the sand core deformation, such as improper raw material ratio and additive ratio. Subsequently, the system automatically adjusts the parameters of the amount of various additives added during the core-making process based on the analysis results. Through this closed-loop feedback and self-regulation mechanism, the core-making equipment can learn and optimize in each production cycle, ensuring that each adjustment is precisely aimed at improving the overall quality and stability of the sand core, thereby fundamentally reducing the generation of defective products and improving production efficiency and product consistency.

[0095] In order to achieve fine control of the performance of the sand core material, the addition amount parameters of each additive are automatically adjusted through the preset addition strategy, specifically:

[0096] The amount of resin added is increased in steps of 0.1 wt% / time. When the amount of resin added reaches the preset upper limit of 1.1 wt%, the amount of anti-veining agent added is decreased in steps of 0.1 wt% / time.

[0097] As mentioned above, the system first uses a step-by-step adjustment method to optimize the resin content, with each adjustment increment being 0.1 weight percent (wt%). This means that if the resin addition ratio set initially does not achieve the ideal sand core performance, the system will gradually increase the resin ratio by this increment until it reaches the preset maximum value of 1.1wt%. This process is intended to improve the strength and adhesion of the sand core by precisely controlling the amount of resin, while avoiding cost increases or process problems caused by excessive addition. When the resin addition reaches the upper limit, in order to balance the material properties and prevent possible negative effects (such as cracking problems caused by over-hardening), the system automatically switches the strategy and begins to reduce the amount of anti-veining agent added according to the same step specification (0.1wt% each time). The gradual reduction of the anti-veining agent helps to control the stress distribution during the resin hardening process, reduce the generation of cracks or veins on the surface and inside of the sand core, and further improve the surface quality of the sand core and the stability of the internal structure. Through this dynamic and precise adjustment strategy, not only the refined management of the proportion of sand core additives is achieved, but also the continuous optimization of material properties is ensured, providing strong technical support for the manufacture of higher quality sand cores.

[0098] Compared with the existing technology, this method realizes the fully automated process of sand core grabbing, dipping, swinging to remove residual materials and drying through the precise operation of the robot arm, which significantly improves the production efficiency; the use of high-precision sensing equipment such as visual sensors and distance sensors ensures the precise positioning and processing of the sand core in each link, and combines the preset dipping depth and preset swinging strategy to improve the uniformity of the coating and the accuracy of thickness control; by real-time monitoring of the deformation of the sand core after drying and comparing it with the preset standard, instant quality assessment is achieved, unqualified products can be quickly identified and isolated, avoiding the waste of resources for further processing, and the instant feedback mechanism provides a basis for the dynamic adjustment of process parameters. It promotes continuous improvement of the production process; combined with the detection data of the laser sensor, the amount of each additive is automatically adjusted through the preset addition strategy, realizing the intelligent optimization of the sand core quality, effectively reducing the quality problems caused by improper additive ratio, and improving the stability and reliability of the sand core; the automated dipping and drying process reduces the excessive use and waste of coatings, and at the same time reduces energy consumption by precisely controlling the drying conditions, meeting the requirements of modern green manufacturing; by integrating advanced automation technology, precision sensing technology and intelligent control strategies, it not only improves the automation level and production efficiency of sand core manufacturing, but also significantly enhances the accuracy of product quality control and the effectiveness of the feedback mechanism.

[0099] The following will be combined with the drawings in this application to clearly and completely describe the technical solutions in this application. Obviously, the described embodiments are part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0100] The main steps in this specific embodiment are as follows Figure 2 As shown, it is a schematic diagram of the process of a specific embodiment of the present application. The automatic dipping and drying scheme of the sand core mainly includes the following steps:

[0101] First, the transfer pallet is sent to the dipping station via the transfer roller line. During this process, the visual sensor confirms whether there is a sand core on the pallet. If there is no sand core on the pallet, it continues to circulate along the regular path; if a sand core is detected, the next step is triggered.

[0102] Once the visual sensor identifies the sand core on the pallet, the system will guide the dip coating robot arm to the correct position (sand core clamping position), fix the pallet through a mechanical device, and ensure that the sand core is waiting in place. The visual sensor on the robot arm fixture further confirms the accuracy of the sand core position to ensure the accuracy of the subsequent clamping action.

[0103] After confirming that the sand core is in the correct position, the robot arm grabs the sand core and immerses it in the coating pool. During this process, the distance sensor controls the immersion depth to prevent the coating from penetrating too deeply into the air pores of the sand core. After dipping, the robot arm will tilt 15° to the left and right and stay for 3 seconds, swinging to remove excess coating from the sand core to ensure uniform coating.

[0104] The robot arm places the processed sand core on a drying tray, which then passes through a drying oven. During the drying process, the paint is completely evaporated and adheres to the surface of the sand core. After leaving the oven, the deformation of the sand core is checked by linear scanning technology. Any sand core with a deformation exceeding 1.5mm will be marked as unqualified and placed in the evaluation area, and an alarm will be triggered.

[0105] The system automatically feeds back the deformation detection results of the sand core after drying to the data platform, and adjusts the amount of anti-veining agent and resin added in subsequent production accordingly. The amount of resin added is increased by 0.1wt% in a step-by-step manner; if the resin reaches the upper limit of 1.1wt%, the amount of anti-veining agent added is reduced in a step-by-step manner, by 0.1wt% each time.

[0106] If the deformation of the sand core is less than 1.5mm, it means that the processing process meets the standards and the robot arm will automatically continue the subsequent assembly work.

[0107] Compared with the prior art, the technical solution proposed in the embodiment of the present application realizes a fully automated process of sand core grabbing, dipping, swinging to remove excess material and drying through the precise operation of the robotic arm, thereby significantly improving production efficiency; high-precision sensing equipment such as visual sensors and range-finding sensors are used to ensure the precise positioning and processing of the sand core in each link, and combined with the preset dipping depth and preset swinging strategy, the uniformity of the coating and the accuracy of thickness control are improved; by real-time monitoring of the deformation of the sand core after drying and comparing it with the preset standard, immediate quality assessment is achieved, unqualified products can be quickly identified and isolated, avoiding waste of resources for further processing, and the dynamic adjustment of process parameters is achieved through this immediate feedback mechanism. It provides a basis and promotes continuous improvement of the production process; combined with the detection data of the laser sensor, the amount of each additive is automatically adjusted through the preset addition strategy, realizing the intelligent optimization of the sand core quality, effectively reducing the quality problems caused by improper additive ratio, and improving the stability and reliability of the sand core; the automated dipping and drying process reduces the excessive use and waste of coatings, and at the same time reduces energy consumption by precisely controlling the drying conditions, meeting the requirements of modern green manufacturing; by integrating advanced automation technology, precision sensing technology and intelligent control strategies, it not only improves the automation level and production efficiency of sand core manufacturing, but also significantly enhances the accuracy of product quality control and the effectiveness of the feedback mechanism.

[0108] Through the description of the above implementation methods, those skilled in the art can clearly understand that the present invention can be implemented by hardware, or by means of software plus a necessary general hardware platform. Based on such an understanding, the technical solution of the present invention can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (which can be a CD-ROM, a USB flash drive, a mobile hard disk, etc.), including a number of instructions for a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in each implementation scenario of the present invention.

[0109] Those skilled in the art will appreciate that the accompanying drawings are merely schematic diagrams of a preferred implementation scenario, and the modules or processes in the accompanying drawings are not necessarily required for implementing the present invention.

[0110] Those skilled in the art will appreciate that the modules in the device in the implementation scenario can be distributed in the device in the implementation scenario according to the implementation scenario description, or can be changed accordingly and located in one or more devices different from the implementation scenario. The modules in the above implementation scenario can be combined into one module, or can be further split into multiple sub-modules.

[0111] The above serial numbers of the present invention are only for description and do not represent the advantages or disadvantages of the implementation scenarios.

[0112] The above disclosure is only a few specific implementation scenarios of the present invention, but the present invention is not limited thereto, and any changes that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. An automatic dipping and drying method for a sand core, characterized in that: The method is applied to a core making system including a robotic arm, and comprises: The sand core is clamped by the mechanical arm and moved to the coating pool, and the movement of the mechanical arm is controlled so that the sand core reaches a preset immersion depth; The mechanical arm is lifted to a preset height, and driven to swing based on a preset swing strategy to prevent the coating on the surface of the sand core from continuously dripping; The swung sand core is moved to a drying furnace to achieve dry adsorption of the coating on the surface of the sand core based on a preset drying strategy; The deformation amount of the sand core after drying is detected and compared with a preset deformation amount threshold, and whether the sand core is qualified is determined according to the comparison result.

2. The method according to claim 1, characterized in that The sand core is clamped by the mechanical arm, specifically: When the transfer tray in the core making system is transferred to the dipping station via the transfer roller line, a visual sensor is used to determine whether the sand core is in the transfer tray; If it is determined that the sand core exists, the transfer tray is stopped and positioned, and the mechanical arm is controlled by the visual sensor to move and clamp the sand core. After the mechanical arm clamps, the transfer tray is released to enter a circular transfer; If it is determined that the sand core does not exist, the transfer tray is allowed to avoid the stop position and circulate normally.

3. The method according to claim 2, characterized in that The visual sensor is used to control the movement of the mechanical arm and to clamp the sand core, specifically: Controlling the robot arm to move to the grabbing position of the sand core through the visual sensor, and determining whether the position of the sand core is the same as the preset position; If the position of the sand core is the same as the preset position, controlling the clamp of the robot arm to clamp the sand core; If the sand core position is different from the preset position, the robot arm is controlled to reset to the initial position and an alarm message is issued.

4. The method according to claim 1, characterized in that The sand core is moved to the coating pool, and the robot arm is controlled to move so that the sand core reaches a preset immersion depth, specifically: The mechanical arm clamps the sand core and moves it into the coating pool, and measures the distance between the mechanical arm clamp and the liquid surface of the coating pool by a distance measuring sensor; When the distance is shortened to a preset distance, the robot arm is controlled to stop descending, so that the sand core reaches a preset immersion depth.

5. The method according to claim 1, characterized in that The mechanical arm is lifted to a preset height, and driven to swing based on a preset swing strategy, specifically: After the mechanical arm clamps the dip-coated sand core and vertically lifts it to a preset height, the mechanical arm is driven to swing based on a preset swing strategy to reduce excess coating on the surface of the sand core; The preset swing strategy is to control the robot arm to tilt in the left and right directions at preset angles in turn and return to the center after staying for a preset time.

6. The method according to claim 1, characterized in that The sand core after dip coating is moved to a drying furnace, and the dry adsorption of the coating on the surface of the sand core is achieved based on a preset drying strategy, specifically: The robot arm places the sand core after dipping on a drying tray of a drying roller line in the core making system, and the drying tray carries the sand core through the drying roller line through a drying furnace; The preset temperature and the preset wind speed of the drying furnace are adjusted based on the preset drying strategy, and the surface coating of the sand core is dried by the drying furnace.

7. The method according to claim 1, characterized in that Detect the deformation of the sand core after drying, and compare it with a preset deformation threshold, and judge whether the sand core is qualified according to the comparison result, specifically: After the sand core is dried out of the furnace, its deformation is detected by scanning with a laser sensor, and the deformation is compared with a preset deformation threshold; If the deformation is less than or equal to , the sand core is judged to be qualified; If the deformation is greater than, the sand core is judged to be unqualified.

8. The method according to claim 7, characterized in that Also includes: When the sand core is judged to be qualified, the mechanical arm is controlled to clamp the sand core for core assembly; When it is determined that the sand core is unqualified, the robot arm is controlled to place the sand core in an area to be evaluated, and at the same time, the detection data of the laser sensor is sent to a data platform and an alarm is issued.

9. The method according to claim 8, characterized in that The detection data of the laser sensor is sent to the data platform, specifically: After the detection data of the laser sensor is sent to the data platform, the core making equipment automatically adjusts the addition amount parameters of each additive based on the detection data through a preset addition strategy to achieve quality optimization of the sand core.

10. The method according to claim 9, characterized in that The addition amount parameters of each additive are automatically adjusted through the preset addition strategy, specifically: The amount of resin added is increased in steps of 0.1 wt% / time. When the amount of resin added reaches the preset upper limit of 1.1 wt%, the amount of anti-veining agent added is decreased in steps of 0.1 wt% / time.

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