A method of automatic dip coating and drying of sand cores

Abstract

The application discloses a kind of automatic dip coating and drying method of sand core, it is related to sand core casting technical field.The method is applied to the core-making system including mechanical arm, the sand core is gripped by the mechanical arm, and the sand core is moved to coating pool, the movement of the mechanical arm is controlled to make the sand core reach preset dip coating depth;The mechanical arm is lifted to preset height, and the mechanical arm is swung based on preset swing strategy to prevent the coating on the surface of the sand core from continuing to drop;The sand core after swinging is moved to drying oven, and based on preset drying strategy to realize the drying adsorption of the coating on the surface of the sand core;The deformation of the sand core after drying is detected, and compared with preset deformation threshold, whether the sand core is qualified according to the comparison result.Not only the accurate control and optimization of sand core manufacturing process are realized, but also the manufacturing quality and production efficiency of sand core are significantly improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sand core casting, in particular to an automatic dipping and drying method of sand core. BACKGROUND

[0002] In the field of casting, sand core is a key component for forming the internal structure of the casting, and its quality directly affects the precision and performance of the final casting. In the traditional sand core manufacturing process, manual operation dominates, especially in the two key steps of dipping and drying. 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 temperature and time, leading to problems such as sand core deformation and cracking. In addition, the lack of automated monitoring means makes it difficult to detect and correct quality problems in the early stages, and defects are often not discovered until the end of the casting process or even later, greatly increasing production costs and cycle time.

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

[0004] The present application provides an automatic dipping and drying method of sand core, which realizes accurate control and optimization of the sand core manufacturing process through highly integrated automation and intelligent technology, and forms a complete closed-loop control from production execution to quality monitoring to parameter feedback adjustment, significantly improving the manufacturing quality and production efficiency of sand core.

[0005] To achieve the above purpose, the present application provides an automatic dipping and drying method of sand core, which is applied to a core making system comprising a mechanical arm, comprising:

[0006] The mechanical arm is used to pick up the sand core and move it to a coating pool, and the movement of the mechanical arm is controlled to make the sand core reach a preset dipping depth;

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

[0008] The sand core after swinging is moved to a drying furnace, and the drying and adsorption of the coating on the surface of the sand core are realized based on a preset drying strategy;

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

[0010] Preferably, the sand core is gripped by the mechanical arm, in particular:

[0011] When the transfer tray in the core-making system is transferred to the dipping station through the transfer roller line, it is determined by the visual sensor whether the sand core exists in the transfer tray;

[0012] If the sand core exists, the transfer tray is stopped and positioned, the mechanical arm is controlled to move and grip the sand core by the visual sensor, and after the mechanical arm is clamped, the transfer tray is released to enter the circulating transfer;

[0013] If the sand core does not exist, the transfer tray is avoided from being stopped and positioned, and normally circulates.

[0014] Preferably, the mechanical arm is controlled to move and grip the sand core by the visual sensor, in particular:

[0015] The mechanical arm is controlled to move to the grabbing position of the sand core by the visual sensor, and it is determined 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, the clamp of the mechanical arm is controlled to grip the sand core;

[0017] If the position of the sand core is not the same as the preset position, the mechanical arm is controlled to reset to the initial position, and an alarm information is sent.

[0018] Preferably, the sand core is moved to the coating pool, and the mechanical arm is controlled to move so that the sand core reaches a preset dipping depth, in particular:

[0019] The mechanical arm clamps the sand core to move and enter the coating pool, and a distance sensor is used to measure the distance between the clamp of the mechanical arm and the liquid level of the coating pool;

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

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

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

[0023] The preset swinging strategy is to control the mechanical arm to tilt by a preset angle in the left and right directions respectively and stay for a preset time, and then return to normal.

[0024] Preferably, after the dipping is completed, the sand core is moved to a drying furnace, and based on a preset drying strategy, the surface coating of the sand core is dried and adsorbed, specifically:

[0025] The mechanical arm places the sand core after the dipping is completed 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 furnace by the drying roller line.

[0026] Based on the preset drying strategy, the preset temperature and preset air speed of the drying furnace are adjusted, 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 threshold, and whether the sand core is qualified is determined according to the comparison result, specifically:

[0028] After the sand core is dried and discharged from the furnace, the deformation amount thereof is detected by a laser sensor and compared with a preset deformation threshold.

[0029] If the deformation amount is less than or equal to the preset deformation threshold, it is determined that the sand core is qualified.

[0030] If the deformation amount is greater than the preset deformation threshold, it is determined that the sand core is unqualified.

[0031] Preferably, it further comprises:

[0032] When it is determined that the sand core is qualified, the mechanical arm is controlled to pick up the sand core for core assembly work.

[0033] When it is determined that the sand core is unqualified, the mechanical arm is controlled to place the sand core in a waiting area, and 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 by a preset addition strategy, so as to optimize the quality of the sand core.

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

[0037] The addition amount of the resin is increased by 0.1wt% per time in turn, and when the addition amount of the resin reaches a preset upper limit of 1.1wt%, the addition amount of the anti-veining agent is reduced by 0.1wt% per time in turn.

[0038] The embodiment of the application discloses a kind of automatic dip coating and drying method of sand core.The method is realized through the accurate operation of mechanical arm, realizes the full automation process of sand core from grabbing, dip coating, swing excess material to drying, significantly improve production efficiency;Using visual sensor and ranging sensor and other high-precision sensing equipment, ensure the accurate positioning and processing of sand core in each link, improve the uniformity of coating and the accuracy of thickness control by combining preset dip coating depth and preset swing strategy;By real-time monitoring the deformation of sand core after drying, and comparing with preset standard, realize instant quality evaluation, unqualified products can be quickly identified and isolated, avoid the waste of further processing resources, through the instant feedback mechanism for the dynamic adjustment of process parameters, promote the continuous improvement of production process;Combined with the detection data of laser sensor, automatically adjust the addition amount of each additive by preset addition strategy, realize the intelligent optimization of sand core quality, effectively reduce the quality problems caused by improper additive ratio, improve the stability and reliability of sand core;Automatic dip coating and drying process reduces the overuse and waste of coating, at the same time, by accurately controlling drying conditions, reduce energy consumption, meet the requirements of modern green manufacturing;By integrating advanced automation technology, precision sensing technology and intelligent control strategy, not only improve the automation level and production efficiency of sand core manufacturing, but also significantly enhance the accuracy of product quality control and the effectiveness of feedback mechanism. BRIEF DESCRIPTION OF DRAWINGS

[0039] In order to more clearly illustrate the technical solutions of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creating laborious work.

[0040] Figure 1 It is a flowchart of the automatic dip coating and drying method of a kind of sand core.

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

[0042] As described in the background, in the traditional sand core manufacturing process, manual dip coating is easy to 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 temperature and time, resulting in problems such as sand core deformation and cracking. In addition, the lack of automated monitoring means makes it difficult to discover and correct quality problems in the early stage, greatly increasing production cost and cycle. In recent years, although some automatic equipment has been introduced into sand core manufacturing, these systems are usually single, only automatic for a part of the work, and cannot form a complete closed-loop control.

[0043] To solve the above problems, the embodiment of the present application provides a sand core automatic dipping and drying method. Through highly integrated automation and intelligent technology, not only the accurate control and optimization of the sand core manufacturing process are realized, 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 core.

[0044] As shown in the flowchart of the sand core automatic dipping and drying method, the method comprises the following steps: Figure 1

[0045] Step S101, the sand core is clamped by the mechanical arm, and the sand core is moved to the paint pool. The mechanical arm is controlled to move so that the sand core reaches a preset dipping depth.

[0046] As described above, the free end of the mechanical arm is provided with a clamp, which can accurately perform the clamping action according to the preset program, ensure the gentle and stable grip of the sand core, and avoid damage or deformation of the sand core during the carrying process. The sand core is driven to move to the paint pool by the mechanical arm. Based on the shape, size and material of the sand core, the ideal dipping depth is set in advance by the control system, and the mechanical arm is controlled by the distance sensor to realize the reasonable dipping of the paint on the surface of the sand core.

[0047] For example, assuming that in a specific embodiment, a cylindrical sand core with a diameter of 10 cm and a length of 20 cm needs to be dipped. First, the best dipping depth is calculated by computer aided design (CAD) software simulation and calculation, which is 1 / 3 of the diameter of the sand core, i.e. about 3.3 cm, to ensure uniform and moderate thickness of the coating. After receiving the instruction, the mechanical arm accurately clamps the sand core and slowly descends to the paint pool, while the distance sensor continuously feeds back data. When the preset depth of 3.3 cm is reached, the mechanical arm stops descending immediately and maintains the depth for a period of time to ensure that the paint penetrates fully, and then rises smoothly to complete the dipping process.

[0048] It should be noted that the adaptive dipping depth adjustment scheme, such as the system automatically fine-tunes the preset dipping depth through algorithm according to the different materials of the sand core (such as sand size, binder type, etc.), realizes more fine control; the intelligent quality monitoring scheme of the paint, such as in the dipping process, the camera installed on the mechanical arm takes pictures of the surface of the sand core in real time, and the image recognition technology is used to analyze the uniformity and integrity of the coating, and if there is any abnormality, it will be immediately fed back to the control system for immediate adjustment or re-dipping, which belongs to the protection scope of the present application.

[0049] Step S102, the mechanical arm is lifted to a preset height, and the mechanical arm is driven to swing based on a preset swinging strategy to prevent the paint 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 lifting height corresponding to the sand core is preset by the control system, and the mechanical arm lifts the sand core to the preset height after completing the dipping coating to avoid the contact between the sand core and the liquid surface of the coating pool when the mechanical arm swings. Subsequently, the mechanical arm swings according to the preset swing strategy to promote the sliding of the excess coating on the surface of the sand core by changing the direction of the gravity, so as to prevent the continuous dripping of the coating on the surface of the sand core, realize the uniform adhesion of the coating on the surface of the sand core, and avoid the damage to the coated coating.

[0051] For example, assuming that the sand core is an elongated cylinder with a diameter of 5 cm and a height of 20 cm. After completing the dipping coating, the mechanical arm will lift the sand core to a height of about 30 cm from the liquid surface of the coating pool to realize the natural dripping of most of the excess coating due to gravity, and ensure the uniform adhesion of the coating on the surface of the sand core. At this time, the preset swing strategy is: first tilt 15 degrees to the left and keep for 3 seconds, then slowly return to normal, then tilt 15 degrees to the right and keep for 3 seconds, then return to normal, and so on for two times. Such gentle and regular swing action helps to promote the sliding of the excess coating on the surface of the sand core, realize the uniform distribution of the coating, and avoid the damage to the coated coating.

[0052] It should be noted that the intelligent dripping detection and dynamic adjustment scheme, such as integrating sensors (such as infrared or weight sensors) to monitor the coating dripping situation in real time while the mechanical arm swings, if the sensor detects that the amount of coating dripping exceeds the expectation, the system will automatically adjust the swing amplitude, frequency or duration to more effectively remove the excess coating while reducing energy consumption; the adaptive swing strategy optimization scheme, such as automatically optimizing the swing strategy according to different sizes, shapes of the sand core and coating characteristics and other factors through machine learning algorithm, the system learns the most efficient swing mode by collecting data after multiple operations to automatically select the optimal solution when facing similar tasks in the future, improve work efficiency and coating quality; the environmental protection and energy saving mode scheme, such as switching to energy saving mode during non-production peak period or when the coating dripping control requirement is not high, using a simplified version of the swing strategy or reducing the swing frequency, thereby saving energy, reducing noise, and maintaining sufficient coating quality control level, all of which are within the protection scope of the present application.

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

[0054] As mentioned above, the mechanical arm holds the sand core after removing the excess material through the gripper at the free end, and accurately moves the sand core into the drying oven. A preset drying strategy is applied to ensure that the paint is evenly and completely dried and firmly adsorbed on the surface of the sand core. This process includes but is not limited to: the mechanical arm accurately controls the sand core to be placed on a specific support or conveyor belt in the drying oven, and then starts the drying program based on the preset drying strategy. The preset drying strategy is customized according to the material of the sand core, the type of paint and the required optimal drying conditions (such as temperature, air speed, time) to achieve the best drying effect and avoid cracking, peeling of the coating or deformation of the sand core.

[0055] For example, assuming that the sand core is a small complex geometric shape, and the surface is coated with a layer of fast-curing epoxy resin paint. The mechanical arm gently places the sand core on a high-temperature stainless steel grid in the drying oven, which is designed to have good air flow to promote uniform drying. The drying oven is started according to the preset drying strategy, with a temperature of 60°C, an air speed of 5 meters per minute, and a duration of 30 minutes, aiming to accelerate the curing process of the resin while ensuring uniform heat distribution to avoid local overheating causing coating defects or damage to the sand core structure.

[0056] It should be noted that the intelligent temperature and humidity control and feedback adjustment scheme, such as introducing environmental sensors to monitor the actual temperature and humidity in the drying oven, and comparing it 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 best drying environment and ensure the consistency of the paint between different batches; multi-mode drying strategy selection scheme, such as according to the specific needs of the sand core, the system provides multiple drying modes for selection, such as fast drying mode for emergency orders, energy saving mode for off-peak hours to save energy, and low temperature long time mode for special coatings sensitive to temperature to protect the integrity of the sand core structure; online monitoring of drying effect and quality prediction scheme, such as integrating infrared imaging or near-infrared spectrometer, real-time monitoring of physical changes (such as moisture content, curing degree) during the drying process of the paint, combining data analysis model to predict the drying end point and coating quality, and early warning of possible drying deficiency or over drying, reducing the generation of defective products, improving the yield, all belong to the protection scope of the present application.

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

[0058] As mentioned above, the deformation of the dried sand core 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 manner. This process includes using high-precision detection equipment such as a laser scanner or a three-dimensional profiler to scan the size and shape of the sand core in all directions to obtain accurate deformation data. Subsequently, the system compares these data with the preset allowable deformation range, and if the deformation does not exceed the threshold, the sand core is determined to be qualified, otherwise it is not qualified and needs to be further processed or discarded.

[0059] For example, large and complex sand cores used for casting automobile engine blocks are scanned using non-contact laser scanning technology after drying, with a resolution of 1 square millimeter to record their three-dimensional geometry. The preset deformation threshold is ±0.5mm in length, ±0.3mm in width and height. After system analysis, if the maximum deformation of the sand core is 0.4mm in length, and no more than 0.2mm in width and height, it is within the allowable range, and the sand core is determined to pass the quality test and is suitable for subsequent casting.

[0060] It should be noted that the real-time deformation correction and feedback adjustment scheme, such as when the sand core deformation exceeds the preset threshold, the system not only can immediately determine the unqualified, but also can try to correct the deformation through subsequent fine adjustment processing (such as local heating, cooling or mechanical compression), while feeding back the deformation data to the previous dipping and drying process to automatically adjust the relevant parameters to 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 sand core deformation is qualified, but other indicators do not meet the requirements, it can also be discovered and processed in time to ensure that the comprehensive performance of the sand core meets the standards; the intelligent prediction and preventive maintenance scheme, such as using big data analysis and machine learning algorithms to predict the trend of sand core deformation based on historical detection data, to adjust process parameters or maintain equipment in advance to avoid potential deformation problems, while analyzing the relationship between deformation and various process parameters to optimize the production process and improve the stability and efficiency of the overall manufacturing, all belong to the protection scope of the present application.

[0061] In order to more intelligently and efficiently automatically grasp the sand core by the mechanical arm, the sand core is gripped by the mechanical arm, specifically:

[0062] When the transfer tray in the core making system is transferred to the dipping station through the transfer roller line, whether the sand core exists in the transfer tray is judged by a visual sensor;

[0063] If the sand core is determined to exist, the transfer tray is stopped and positioned, the mechanical arm is controlled to move and clamp the sand core by the visual sensor, and after the mechanical arm clamps, the transfer tray is released to enter the circulation transfer;

[0064] If the sand core is determined to not exist, the transfer tray is avoided from being stopped and positioned, and the normal circulation transfer is performed.

[0065] As described above, the transfer tray carrying the sand core travels along the transfer roller to the dipping coating area, at which time the visual sensor is intervened to work, and whether the sand core exists on the transfer tray is checked by the visual sensor. After confirming the existence of the sand core, the system makes the tray pause and accurately align, and then the visual sensor guides the mechanical arm to accurately move above the sand core, and the sand core is safely clamped by the clamp. After the clamping is successful, the tray is released from the pause and returns to the circulation transportation process. If the sensor detects no sand core, the tray directly continues its circulation path without stopping. This optimization combines the cooperative work of visual detection and the mechanical arm to ensure the efficient operation of the process and the reasonable allocation of resources.

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

[0067] The mechanical arm is controlled to move to the grabbing position of the sand core by the visual sensor, and whether the position of the sand core is the same as the preset position is determined;

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

[0069] If the position of the sand core is not the same as the preset position, the mechanical arm is controlled to reset to the initial position, and an alarm information is sent.

[0070] As described above, in the optimized automatic grabbing process, the visual sensor first accurately positions the actual position of the sand core on the transfer tray, and then the system compares and verifies this position with the preset ideal grabbing position. When it is confirmed that the position of the sand core is consistent with the preset position, the control system will instruct the mechanical arm to move to this position according to the guidance of the visual sensor, and start the clamp to smoothly clamp the sand core. Once a position deviation is found, the mechanical arm will be instructed to return to the initial safe position, and an alarm notification will be triggered immediately to avoid incorrect operation and ensure the accuracy and safety of the work. The whole process embodies the efficient integration of accurate control and exception management of automatic operation.

[0071] In order to improve the quality and efficiency of the sand core coating, the sand core is moved to the coating pool, and the mechanical arm is controlled to move to make the sand core reach a preset dipping coating depth, specifically:

[0072] The mechanical arm holds the sand core and moves into the coating pool, and a distance measuring sensor is used to measure the distance between the mechanical arm clamp and the liquid level of the coating pool.

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

[0074] As described above, the mechanical arm holds the sand core and gradually descends into the coating pool. During this process, a distance measuring sensor installed on the mechanical arm continuously monitors the vertical distance from the bottom of the clamp to the liquid level of the coating. A preset dipping depth is calculated according to the characteristics of the sand core and the requirements of the coating. Once the sensor detects that the current distance is equal to the preset dipping depth value, the control system responds immediately and instructs the mechanical arm to pause the diving action. This ensures that the sand core is immersed in the coating to the right depth, neither too shallow to affect the uniformity of the coating, nor too deep to cause the coating to block the pores and waste, thereby optimizing resource utilization while ensuring the quality and efficiency of the coating.

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

[0076] After the mechanical arm holds the sand core after dipping and vertically lifts it to a preset height, the mechanical arm is driven to swing based on a preset swinging strategy to reduce the excess coating on the surface of the sand core.

[0077] The preset swinging strategy is to control the mechanical arm to tilt by a preset angle in the left and right directions respectively and stay for a preset time before returning to the vertical position.

[0078] As described above, first, the mechanical arm holds the sand core after dipping and vertically lifts it to a preset height. This height is set to ensure that the excess coating on the surface of the sand core can be effectively removed during the subsequent swinging process without affecting the structure of the sand core or the coated coating due to excessive swinging amplitude. Then, according to the preset swinging strategy, the mechanical arm starts to swing orderly. The specific strategy is that the mechanical arm first tilts to the left by a preset angle and stays at this position for a preset time to allow the excess coating loosened by gravity to naturally fall off. Then, the mechanical arm returns to the vertical position and tilts to the right by the same angle, also stays for the same time to ensure that the excess coating is effectively removed. This left-right swinging action is repeated until the preset number of times or the effect meets the requirements. Finally, the mechanical arm returns to the vertical position, completing the process of removing excess coating and achieving efficient and gentle reduction of excess coating on the surface of the sand core.

[0079] In order to improve the quality and efficiency of drying, the sand core after dipping is moved to a drying oven, and the surface coating of the sand core is dried and adsorbed based on a preset drying strategy, specifically:

[0080] The mechanical arm places the sand core after dip coating on the drying tray of the drying roller line in the core making system, and the drying tray carrying the sand core passes through the drying furnace by the drying roller line;

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

[0082] As mentioned above, the mechanical arm places the sand core on the drying tray in the core making system, and the drying tray equipped with the sand core is sent into the drying furnace, which is guided by the drying roller line to pass through the furnace smoothly, realizing the drying and curing of the coating. The drying process strictly follows the preset drying strategy, which is set in advance according to factors such as 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, aiming to create the most suitable drying environment. Suitable temperature accelerates the evaporation of coating moisture, while carefully controlled wind speed promotes air circulation, helping the surface coating to dry evenly. At the same time, it avoids the defects of the coating caused by local overheating or uneven drying, such as cracking, peeling, etc. Through such precise control, not only the drying efficiency is improved, but also the perfect adsorption and formation of the sand core surface coating are ensured.

[0083] In order to find the deformation quality problem of the sand core in time, the deformation amount of the sand core after drying is detected and compared with the preset deformation amount threshold, 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, the deformation amount thereof is detected by a laser sensor, and the deformation amount is compared with a preset deformation amount threshold;

[0085] If the deformation amount is less than or equal to the preset deformation amount threshold, it is judged that the sand core is qualified;

[0086] If the deformation amount is greater than the preset deformation amount threshold, it is judged that the sand core is unqualified.

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

[0088] To ensure and improve the quality of the sand core, the following steps are also included:

[0089] When it is determined that the sand core is qualified, the mechanical arm is controlled to pick up the sand core for core assembly work;

[0090] When it is determined that the sand core is unqualified, the mechanical arm is controlled to place the sand core in the evaluation area, and the detection data of the laser sensor is sent to the data platform, and an alarm is issued.

[0091] As mentioned above, once the system determines that the deformation of the dried sand core is qualified, it means that it meets the standard for further processing. At this time, the mechanical arm will automatically execute the next process, i.e., accurately pick up the qualified sand core and transport it to the next station for core assembly work, ensuring seamless connection and efficiency of the production process. Conversely, if the detection result shows that the sand core deformation exceeds the standard and is considered unqualified, the mechanical arm will follow another set of pre-set instructions to safely place the unqualified sand core in a specific evaluation area. At the same time, all detection data collected by the laser sensor related to unqualified determination will be transmitted to the central data platform in real time. This is aimed at collecting and analyzing information about defective products to provide data support for subsequent process improvement and quality control. In addition, the system will trigger an alarm signal to notify relevant personnel to pay attention to handling and reviewing the unqualified sand core, preventing defective products from flowing into the next process and ensuring strict control of product quality.

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

[0093] After sending the detection data of the laser sensor to the data platform, the core making equipment automatically adjusts the addition amount parameters of each additive based on the detection data through a pre-set addition strategy, achieving optimization of the quality of the sand core.

[0094] As mentioned above, the detailed data obtained after the laser sensor completes detection will be transmitted to the central data platform in real time. This data platform serves as the hub for information aggregation and analysis, receiving and processing real-time data from various sensors. Based on these accurate detection results, the control system of the core-making equipment automatically activates the preset strategy algorithm, which can intelligently analyze the possible factors causing deformation, such as improper raw material ratio and improper additive proportion. Subsequently, the system automatically adjusts the addition amount parameters of various additives in the core-making process based on the analysis results. Through this closed-loop feedback and self-adjusting mechanism, the core-making equipment can learn and optimize in each production cycle, ensuring that each adjustment is precisely directed to improve the overall quality and stability of the sand core, thereby fundamentally reducing the production of defective products and improving production efficiency and product consistency.

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

[0096] The addition amount of resin is increased by 0.1 wt% per step, and when the addition amount of resin reaches the preset upper limit of 1.1 wt%, the addition amount of anti-veining agent is decreased by 0.1 wt% per step.

[0097] As mentioned above, the system first uses a step-by-step adjustment method to optimize the content of resin, with an increment of 0.1 weight percent (wt%) per adjustment. This means that if the initial resin addition ratio does not achieve the desired sand core performance, the system will gradually increase the resin ratio by this increment until it reaches the preset maximum value of 1.1 wt%. This process aims to improve the strength and adhesion of the sand core by precisely controlling the amount of resin, while avoiding the cost increase or process problems caused by excessive addition. When the resin addition amount reaches the upper limit, in order to balance the material performance and prevent possible negative effects (such as crack problems caused by excessive hardening), the system automatically switches strategies and starts to decrease the addition amount of anti-veining agent by the same step size (0.1 wt% per step). Gradual reduction of anti-veining agent helps to control stress distribution during resin hardening, reducing the generation of cracks or veins on the surface and inside of the sand core, thereby further improving the surface quality and stability of the internal structure of the sand core. Through this dynamic and precise adjustment strategy, not only is the proportion of sand core additives precisely managed, but the continuous optimization of material performance is also ensured, providing strong technical support for manufacturing higher quality sand cores.

[0098] Compared with the prior art, the method realizes the full-automatic process of sand core from grabbing, dip coating, swinging excess material to drying through precise operation of the mechanical arm, significantly improves the production efficiency; the precise positioning and processing of the sand core in each link are ensured by using high-precision sensing devices such as visual sensors and distance measuring sensors, the uniformity of the coating and the accuracy of the thickness control are improved by combining the preset dip coating depth and the preset swinging strategy; the real-time quality evaluation is realized by comparing the deformation amount of the sand core after drying with the preset standard, the unqualified products can be quickly identified and isolated, the resource waste of further processing is avoided, the dynamic adjustment of the process parameters is provided through the instant feedback mechanism, and the continuous improvement of the production process is promoted; the intelligent optimization of the sand core quality is realized by automatically adjusting the addition amount of each additive through the preset addition strategy combined with the detection data of the laser sensor, the quality problems caused by improper additive ratio are effectively reduced, and the stability and reliability of the sand core are improved; the automatic dip coating and drying process reduces the overuse and waste of coating, and the energy consumption is reduced by accurately controlling the drying conditions, which meets the requirements of modern green manufacturing; by integrating advanced automation technology, precise sensing technology and intelligent control strategy, not only the automation level and production efficiency of the sand core manufacturing are improved, but also the accuracy of the product quality control and the effectiveness of the feedback mechanism are significantly enhanced.

[0099] The technical solutions in the present application will be described clearly and completely in combination with the drawings in the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor belong to the scope of protection of the present application.

[0100] The main steps in the specific embodiment are as shown in Figure 2 The automatic dip coating and drying scheme of the sand core mainly includes the following steps:

[0101] Firstly, the transfer tray is sent to the dip coating station through the transfer roller line, and whether the tray carries the sand core is confirmed by the visual sensor during the process. If the tray has no sand core, it continues to circulate along the normal path; if the sand core is detected, the next operation is triggered.

[0102] Once the visual sensor identifies the sand core on the tray, the system guides the dip coating mechanical arm to the correct position (sand core clamping position), fixes the tray through the mechanical device to ensure that the sand core waits in place. The visual sensor on the mechanical arm clamp further confirms the accuracy of the sand core position to ensure the accuracy of the subsequent clamping action.

[0103] After confirming the correct position of the sand core, the mechanical arm picks up the sand core and immerses it in the coating pool. The immersion depth is controlled by a distance measuring sensor to prevent the coating from penetrating too deeply into the sand core's air vents. After immersion, the mechanical arm tilts left and right by 15° and stays for 3s. The tilting removes excess coating and ensures uniform coating.

[0104] The treated sand core is placed on a drying tray, which is then passed through a drying oven. During drying, the coating's moisture is completely evaporated and adheres tightly to the sand core's surface. After exiting the oven, the sand core's deformation is checked using linear scanning technology. Any sand core with deformation exceeding 1.5mm is marked as unqualified and placed in the evaluation area, triggering an alarm.

[0105] The system automatically feeds back the deformation detection results of the sand core after drying to the data platform, and adjusts the addition amount of anti-veining agent and resin in subsequent production accordingly. The addition amount of resin is preferentially increased by 0.1wt% in a stepwise manner. If the resin reaches the upper limit of 1.1wt%, the addition amount of anti-veining agent is then decreased by 0.1wt% in a stepwise manner.

[0106] If the sand core deformation is less than 1.5mm, indicating that the treatment process meets the standard, the mechanical arm will automatically continue the subsequent assembly work.

[0107] Compared with the prior art, the technical scheme proposed in the embodiments of the application realizes full automation of the sand core from grabbing, immersion, swing removal to drying through precise operation of the mechanical arm, significantly improving production efficiency. The use of high-precision sensing devices such as visual sensors and distance measuring sensors ensures accurate positioning and processing of the sand core at each link, improves the uniformity of the coating and the accuracy of thickness control by combining with the preset immersion depth and preset swing strategy. By monitoring the deformation of the sand core after drying in real time and comparing it with the preset standard, immediate quality evaluation is realized, unqualified products can be quickly identified and isolated, avoiding further processing resource waste. The immediate feedback mechanism provides a basis for dynamic adjustment of process parameters, promoting continuous improvement of the production process. Combined with the detection data of the laser sensor, the addition amount of each additive is automatically adjusted through the preset addition strategy, realizing intelligent optimization of the quality of the sand core, effectively reducing quality problems caused by improper addition of additives, and improving the stability and reliability of the sand core. The automated immersion and drying process reduces the overuse and waste of coating, and by precisely controlling the drying conditions, energy consumption is reduced, meeting the requirements of modern green manufacturing. By integrating advanced automation technology, precision sensing technology and intelligent control strategy, 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.

[0108] Those skilled in the art can clearly understand the present application through the above description of the embodiments that the present application can be implemented by hardware or by means of software and necessary universal hardware platform. Based on such understanding, the technical solutions of the present application 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 U disk, a mobile hard disk, etc.) and includes a plurality of instructions for causing a computer device (which can be a personal computer, a server, or a network device, etc.) to execute the methods described in various embodiments of the present application.

[0109] Those skilled in the art can understand that the drawings are only schematic of a preferred embodiment, and the modules or flows in the drawings are not necessarily required for implementing the present application.

[0110] Those skilled in the art can understand that the modules in the apparatus in the embodiments can be distributed in the apparatus in the embodiments as described or can be changed to be located in one or more apparatuses different from the embodiments. The modules in the above embodiments can be combined into one module or can be further split into a plurality of sub-modules.

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

[0112] The above disclosure is only several specific embodiments of the present application, but the present application is not limited thereto, and any changes that can be thought of by those skilled in the art shall fall within the protection scope of the present application.

Claims

1. A method of automatic dip coating and drying of sand cores, characterized in that The method is applied to a core-making system comprising a mechanical arm, and comprises the following steps: The mechanical arm is controlled to move the sand core to a coating pool, and the movement of the mechanical arm is controlled to make the sand core reach a preset dipping depth; The mechanical arm is lifted to a preset height, and the mechanical arm is driven to swing based on a preset swinging strategy to prevent the coating on the surface of the sand core from continuously dripping; The sand core after swinging is moved to a drying oven, and drying adsorption of the coating on the surface of the sand core is realized based on a preset drying strategy; The deformation amount of the sand core after drying is detected and compared with a preset deformation threshold, and whether the sand core is qualified is determined according to the comparison result; The mechanical arm is lifted to a preset height, and the mechanical arm is driven to swing based on a preset swinging strategy, specifically: After the mechanical arm holding the sand core after dipping is vertically lifted to a preset height, the mechanical arm is driven to swing based on a preset swinging strategy to reduce the excess coating on the surface of the sand core; The preset swinging strategy is to control the mechanical arm to tilt by a preset angle in the left and right directions respectively and stay for a preset time, and then return to normal; The deformation amount of the sand core after drying is detected and compared with a preset deformation threshold, and whether the sand core is qualified is determined according to the comparison result, specifically: After the sand core is taken out of the drying oven, the deformation amount of the sand core is detected by a laser sensor, and the deformation amount is compared with a preset deformation threshold; If the deformation amount is less than or equal to the preset deformation threshold, it is determined that the sand core is qualified; If the deformation amount is greater than the preset deformation threshold, it is determined that the sand core is unqualified; When it is determined that the sand core is qualified, the mechanical arm is controlled to clamp the sand core for core assembly work; When it is determined that the sand core is unqualified, the mechanical arm is controlled to place the sand core in a waiting area, and the detection data of the laser sensor is sent to a data platform, and an alarm is issued; 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 system automatically adjusts the addition amount parameters of each additive based on the detection data through a preset addition strategy, so as to optimize the quality of the sand core. The sand core is clamped by the mechanical arm, specifically:

2. The method of claim 1, wherein, When a transfer tray in the core-making system is transferred to a dipping station through a transfer roller line, it is determined by a visual sensor whether the sand core exists in the transfer tray; If it is determined that the sand core exists, the transfer tray is stopped and positioned, the mechanical arm is controlled to move and clamp the sand core by the visual sensor, and after the mechanical arm is clamped, the transfer tray is released to enter a circulating transfer; If it is determined that the sand core does not exist, the transfer tray is avoided from being stopped and positioned, and normally circulates. The mechanical arm is controlled to move and clamp the sand core by the visual sensor, specifically:

3. The method of claim 2, wherein, The mechanical arm is controlled to move to a grabbing position of the sand core by the visual sensor, and it is determined whether the position of the sand core is the same as a preset position; If the position of the sand core is the same as the preset position, the clamp of the mechanical arm clamps the sand core; ​ If the sand core position is not the same as the preset position, the mechanical arm is controlled to reset to the initial position, and an alarm information is sent out.

4. The method of claim 1, wherein, The sand core is moved to a coating pool, and the mechanical arm is controlled to move so that the sand core reaches a preset dipping coating depth, specifically: The mechanical arm holds the sand core to move and enter the coating pool, and a distance measuring sensor is used to measure the distance between the mechanical arm clamp and the liquid level of the coating pool; When the distance is shortened to a preset distance, the mechanical arm is controlled to stop descending, so that the sand core reaches the preset dipping coating depth.

5. The method of claim 1, wherein, After the dipping coating is completed, the sand core is moved to a drying furnace, and based on a preset drying strategy, the surface coating of the sand core is dried and adsorbed, specifically: The mechanical arm places the sand core after the dipping coating is completed on a drying tray of a drying roller line in the core making system, the drying tray carries the sand core through the drying furnace by the drying roller line; Based on the preset drying strategy, the preset temperature and preset air speed of the drying furnace are adjusted, and the surface coating of the sand core is dried by the drying furnace.

6. The method of claim 1, wherein, The addition amount parameters of each additive are automatically adjusted by a preset addition strategy, specifically: The addition amount of the resin is increased by 0.1wt% per time in turn, and when the addition amount of the resin reaches a preset upper limit of 1.1wt%, the addition amount of the anti-veining agent is reduced by 0.1wt% per time in turn.

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