Control device and control method

Abstract

To provide a control device and a control method, capable of promptly identifying mold defects in the molding of a mold using a batch mixer.SOLUTION: A control device 21 of the present invention controls the supply of a plurality of liquid chemicals, including a resin and a hardener, to a batch mixer 2, by means of each supply device 12 corresponding to these liquids, wherein the control device includes: a flow rate measuring part 30 for measuring the flow rates of the liquid chemicals; a supply volume calculation part 31 for calculating the amount of liquid chemical supplied per batch; an error determination part 32 for determining whether an error between a target amount of liquid chemical and the amount of liquid chemical supplied, calculated by the supply volume calculation part 31, exceeds a threshold value; and a notification processing part 33 for performing processing to cause a notification device 26 to perform a notification when the error determination part 32 determines that the error exceeds the threshold value.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to the manufacture of molds using a batch mixer. [Background technology]

[0002] Conventionally, mixers for making casting molds include continuous mixers that continuously supply liquid materials such as resin and hardener, and sand material and knead them, and batch mixers that supply sand material and liquid materials for each process (each batch) and knead them. In addition, various technologies have been provided for controlling the amount of liquid materials supplied when making casting molds.

[0003] For example, the applicant of the present application has provided a mold making support system in which manufacturing information can be confirmed for each mold in the following Patent Document 1. The mold making support system in the following Patent Document 1 makes it possible to properly manage manufacturing information and support sound mold making by making it possible to confirm manufacturing information for each mold. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2021-154316 A Summary of the Invention [Problem to be solved by the invention]

[0005] Here, in a batch mixer, the liquid is supplied for each process, so the challenge is to reduce the error between the target amount of liquid and the amount actually supplied. Also, while an experienced person may be able to judge whether the liquid is excessive or insufficient from the state of the mold material after kneading, it is difficult for an inexperienced person to judge whether the liquid is excessive or insufficient by visual inspection, etc.

[0006] In addition, if a mold material with an excess or deficiency of liquid is used as a mold, defects in the mold may lead to defective castings. In addition, when molding molds using a batch mixer, there is a need to quickly identify defects in the mold (before the casting is manufactured).

[0007] Therefore, an object of the present invention is to provide a control device and a control method that can quickly detect mold defects when molding a mold using a batch mixer. [Means for solving the problem]

[0008] (1) The control device of the present invention, provided to solve the above-mentioned problems, is a control device that controls the supply of multiple types of liquids, including a resin and a hardener, to a batch mixer using respective supply devices corresponding to the liquids, and is characterized in having a flow rate measurement unit that measures the flow rate of the liquid, a supply amount calculation unit that calculates the amount of the liquid supplied per batch using the flow rate during a predetermined period of time measured by the flow rate measurement unit, an error judgment unit that determines whether an error between a predetermined target amount of the liquid per batch and the amount of the liquid supplied per batch calculated by the supply amount calculation unit exceeds a threshold value, and an alarm processing unit that performs processing to cause an alarm device to issue an alarm when the error judgment unit determines that the error exceeds the threshold value.

[0009] In the control device of the present invention, in the molding of a mold using a batch mixer, the error between the supply amount per batch and the target amount of the liquid is automatically calculated, and when the error exceeds a threshold value, the notification device is made to execute a notification. For example, when there is a possibility that an excess or shortage (error) of the liquid may lead to a defective mold, the control device of the present invention makes the notification device execute a notification such as an alarm sound (alert). In this way, the control device of the present invention can promptly notify an operator of the excess or shortage of the supply amount of the liquid per batch. As a result, the control device of the present invention allows an operator to promptly grasp that the mold may be defective. For example, according to the control device of the present invention, even an inexperienced or inexperienced person can promptly grasp the defect of the mold. As a result, the control device of the present invention allows an operator to grasp the defect of the mold before the production of the casting, and suppress the occurrence of defective castings.

[0010] (2) In the control device of the present invention, when the supply device has a flow path that returns the liquid to a tank and is capable of circulating the liquid, the flow rate measuring unit measures an instantaneous flow rate of the liquid during a predetermined time period transported by the circulating supply device and an accumulated number of times of the instantaneous flow rate, and the supply amount calculation unit calculates an amount of the liquid supplied per batch for the liquid transported by the circulating supply device using the instantaneous flow rate and the accumulated number of times measured by the flow rate measuring unit.

[0011] According to the above-mentioned configuration, the flow rate of the circulating supply device can be appropriately measured, the amount of the liquid actually supplied to the batch mixer can be calculated with higher accuracy, and the error from the target amount can be calculated with higher accuracy. As a result, the control device of the present invention can accurately notify the excess or shortage of the liquid.

[0012] (3) In the control device of the present invention, when the supply device does not have a flow path for returning the liquid to a tank and circulating it, is defined as a non-circulating supply device, the flow rate measuring unit measures the number of pulses output from a flow meter during a predetermined time for the liquid transported by the non-circulating supply device, and the supply amount calculation unit calculates the amount of the liquid supplied per batch using the number of pulses measured by the flow rate measuring unit for the liquid transported by the non-circulating supply device.

[0013] According to the above-mentioned configuration, the flow rate of the non-circulating supply device can be appropriately measured, the amount of the liquid actually supplied to the batch mixer can be calculated with higher accuracy, and the error from the target amount can be calculated with higher accuracy. As a result, the control device of the present invention can accurately notify the excess or shortage of the liquid.

[0014] (4) In the control device of the present invention, the supply device is provided with a pump that transports the liquid agent, and the control device includes a pump constant calculation unit that calculates a pump constant that indicates performance of the pump, and a pump constant setting unit that sets the pump constant, wherein the pump constant calculation unit calculates the pump constant using an ejection amount of the liquid agent when the liquid agent is ejected for a predetermined time and an operating frequency of the pump, and the pump constant setting unit stores the pump constant calculated by the pump constant calculation unit as a new pump constant.

[0015] According to the above-mentioned configuration, even if the pump performance changes due to factors such as pump deterioration, it is possible to flexibly respond. Specifically, according to the control device of the present invention, when the pump performance changes, the pump constant can be updated, thereby readjusting the pump operation frequency. As a result, the control device of the present invention can supply a liquid agent at an amount with an extremely small error from the target amount even if the pump performance changes. In other words, according to the control device of the present invention, a supply amount with a small error can be preferably maintained, and mold defects can be suppressed.

[0016] (5) In the control device of the present invention, a non-circulating supply device is one of the supply devices that does not have a flow path for returning the liquid to a tank and circulating it, and a time set as a supply time of the liquid to the batch mixer is a cut-out time. The flow rate measuring unit measures the number of pulses output from a flow meter for the liquid transported by the non-circulating supply device over a specific time from the start of the cut-out time to a specific timing after the end of the cut-out time, and the supply amount calculation unit calculates the amount of the liquid supplied per batch for the liquid transported by the non-circulating supply device using the number of pulses during the specific time measured by the flow rate measuring unit.

[0017] According to the above-mentioned configuration, it is possible to calculate the supply amount per batch, including the amount of liquid dripping in after the pump is stopped. As a result, the control device of the present invention can calculate the supply amount of liquid with higher accuracy when a non-circulating supply device is used. In addition, the control device of the present invention can improve the accuracy of error determination by improving the calculation accuracy of the supply amount of liquid, and can improve the accuracy of mold defect notification.

[0018] (6) The control method of the present invention is a control method for controlling the supply of multiple types of liquids, including a resin and a hardener, to a batch mixer using respective supply devices corresponding to the liquids, and is characterized in including: a flow rate measurement step for measuring a flow rate of the liquid; a supply amount calculation step for calculating an amount of the liquid supplied per batch using the flow rate during a predetermined time period measured in the flow rate measurement step; an error determination step for determining whether an error between a predetermined target amount of the liquid per batch and the amount of the liquid supplied per batch calculated in the supply amount calculation step exceeds a threshold value; and an alarm processing step for causing an alarm device to execute an alarm when it is determined in the error determination step that the error exceeds the threshold value.

[0019] In the control method of the present invention, in the molding of a mold using a batch mixer, the error between the supply amount per batch and the target amount is automatically calculated, and when the error exceeds a threshold value, the notification device is made to execute a notification. For example, in the control method of the present invention, when there is a possibility that an excess or shortage (error) of the liquid agent may lead to a defective mold, the notification device is made to execute a notification such as an alarm sound (alert). In this way, in the control method of the present invention, when there is an excess or shortage in the supply amount of the liquid agent per batch, the control method of the present invention can promptly notify the operator of this fact. As a result, the control method of the present invention allows the operator to promptly grasp that the mold may be defective. For example, according to the control method of the present invention, even an inexperienced or inexperienced person can promptly grasp the defect of the mold. As a result, the control method of the present invention allows the operator to grasp the defect of the mold before the production of the casting, and suppress the occurrence of defective castings. Effect of the Invention

[0020] According to the present invention, it is possible to provide a control device and a control method that can quickly detect mold defects in molding using a batch mixer. [Brief description of the drawings]

[0021] [Figure 1] FIG. 1 is a conceptual diagram showing the configuration of a mold making device using a controller according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a functional block diagram of the auto feeder (controller). [Diagram 3] FIG. 2 is a schematic diagram showing a circulating supply device and a non-circulating supply device. [Figure 4] FIG. 2 is a schematic diagram showing a configuration example of a supply device. [Diagram 5] FIG. 2 is a schematic diagram showing a continuous mixer and a batch mixer. [Figure 6] 6 is a diagram showing the relationship between the output timing of various signals and the extraction time. FIG. [Figure 7] FIG. 4 is a diagram showing the relationship between various signals, cut-out time, and automatic driving time. [Figure 8]4 is a timing chart showing control during normal operation of the circulating supply device. [Figure 9] FIG. 13 is a diagram showing a process during normal operation for the circulation type executed by the controller. [Figure 10] FIG. 13 is a diagram showing an example of calculation of the supply amount in the case of a circulation type. [Figure 11] 4 is a timing chart showing control during normal operation of the non-circulating supply device. [Figure 12] FIG. 13 is a diagram showing a process during normal operation for a non-circulating type executed by a controller. [Figure 13] 13 is a timing chart showing pulse measurement times in the case of a non-circular system. [Figure 14] 11 is a timing chart showing control during a calibration mode for resetting a pump constant. [Figure 15] FIG. 13 is a diagram showing a process during a calibration mode for resetting a pump constant executed by the controller. [Figure 16] FIG. 11 is a diagram showing a first calibration operation process executed by the controller. [Figure 17] FIG. 13 is a diagram illustrating a cutting-out time setting process executed by the controller. [Figure 18] FIG. 13 is a diagram showing an example of a screen displayed on the display device during a calibration mode. [Figure 19] FIG. 2 is a schematic diagram showing a mold-making device for making a gas-hardening mold. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] (1. Configuration of the casting molding device) Hereinafter, a controller 21 (control device) and a control method according to an embodiment of the present invention will be described with reference to the drawings.

[0023] Fig. 1 is a conceptual diagram showing the configuration of a mold making apparatus 1 for manufacturing a mold. As shown in Fig. 1, the mold making apparatus 1 includes a batch mixer 2, a sand hopper 4, an auto-feeder 20, a plurality of tanks 7, a plurality of pumps 8, a plurality of flow meters 9, a plurality of solenoid valves 10, and a temperature sensor 5. Also, as shown in Fig. 1, the auto-feeder 20 is capable of communicating with a server 50.

[0024] The mold making apparatus 1 shown as an example in FIG. 1 is for manufacturing a self-hardening mold. The "self-hardening mold" is a method of making a mold by putting mixed sand, which is made by mixing refractory particles (sand material) and a liquid agent, into a frame and leaving it at room temperature to harden the sand. The controller 21 (control device) of the present invention can be applied to the mold making apparatus 200 relating to a method (cold box) for manufacturing a gas-hardening mold, in addition to the mold making apparatus 1 for manufacturing a self-hardening mold. The cold box is a molding method in which a hardening catalyst (e.g., amine gas) is sprayed onto mixed sand, which is made by mixing refractory particles (sand material) with a liquid agent (e.g., amine gas-hardening phenolic urethane resin), to instantly mold a mold. The mold making apparatus 200 relating to the cold box will be described later with reference to FIG. 19.

[0025] The tank 7, the pump 8, the solenoid valve 10, and the piping 11 constitute a supply device 12 for supplying a liquid material to the batch mixer 2. As shown in Fig. 1, the supply device 12 is provided with a flow meter 9. The mold molding apparatus 1 shown as an example in Fig. 1 is provided with three supply devices 12. Specifically, the mold molding apparatus 1 includes a supply device 12 for supplying a resin, a supply device 12 for supplying a retarder, and a supply device 12 for supplying a rapid-hardening agent.

[0026] 1 includes a tank 7, a pump 8, a flowmeter 9, an electromagnetic valve 10, and piping 11. Specifically, the supplying device 12 for supplying resin includes a tank 7A (resin tank), a pump 8A (resin pump), a flowmeter 9A, an electromagnetic valve 10A, and piping 11. The supplying device 12 for supplying a retarding agent includes a tank 7B (retarding agent tank), a pump 8B (retarding agent pump), a flowmeter 9B, an electromagnetic valve 10B, and piping 11. The supplying device 12 for supplying a fast-hardening agent includes a tank 7C (fast-hardening agent tank), a pump 8C (fast-hardening agent pump), a flowmeter 9C, an electromagnetic valve 10C, and piping 11.

[0027] As will be described later, the mold manufacturing apparatus in which the control device (controller) of the present invention is used is not limited to one having three supply devices 12, and may be one having two supply devices 12. Furthermore, the mold making apparatus 1 in which the control device of the present invention is used may not be one in which the solenoid valve 10 is provided in the supply device 12.

[0028] In the mold making apparatus 1, a sand mold is made as a mold. In the mold making apparatus 1, a plurality of types of liquid agents (resin and hardener) are added to refractory particles (sand material) and kneaded to prepare a mold material, and the mold material is supplied to a frame 6 to manufacture a mold (sand mold).

[0029] The auto feeder 20 is used to control the amount of liquid supplied to the batch mixer 2. The auto feeder 20 is used in the batch mixer 2, and supplies a plurality of types of liquid including a resin and a hardener to the batch mixer 2 using the corresponding supply devices 12. The controller 21 (control device) according to the embodiment of the present invention is provided in the auto feeder 20. That is, the controller 21 (control device) according to the embodiment of the present invention is also used in the batch mixer 2. The configuration of the auto feeder 20 will be described in detail later.

[0030] Examples of the refractory particles (sand material) used as the mold material include single sand and mixed sand. Examples of the single sand and mixed sand include silica sand, zircon, chromite, olivine, alumina, synthetic mullite, etc. As the single sand and mixed sand, either new sand or recycled sand may be used.

[0031] Resins used as mold materials include, for example, organic self-hardening resins and inorganic self-hardening resins. Examples of organic self-hardening resins include, for example, acid-hardening resins and ester-hardening resins. Examples of acid-hardening resins include, for example, furan resins and phenolic resins. Examples of ester-hardening resins include, for example, alkaline phenolic resins. Examples of inorganic self-hardening resins include, for example, water glass. Examples of resins (gas-hardening resins) used when molding a gas-hardening mold include, for example, amine gas-hardening phenolic urethane resins and CO2-hardening water glass.

[0032] Furthermore, as the hardener used as the mold material, when the resin is an organic self-hardening resin, it is possible to use an acidic hardening catalyst containing sulfuric acid, phosphoric acid, or organic sulfonic acid, which is classified into fast-hardening and slow-hardening types by adjusting the acid strength and acid concentration, or an organic ester whose hardening speed can be adjusted depending on the degree of hydrolysis and the degree of compatibility. Also, when the resin is an inorganic self-hardening resin, it is possible to use an organic ester whose hardening speed can be adjusted depending on the degree of hydrolysis and the degree of compatibility.

[0033] The batch mixer 2 using the auto feeder 20 equipped with the controller 21 of the present invention may use one type of hardener, or may use two types of hardeners, a slow hardening agent and a fast hardening agent.

[0034] (2. Batch Mixer Configuration) The batch mixer 2 is for mixing refractory particles, resin, and a hardener to produce a mold material (mixed sand). The batch mixer 2 is supplied with refractory particles stored in a sand hopper 4 and liquid materials (resin and hardener) stored in each tank 7.

[0035] The batch mixer 2 is also provided with a batch mixer control device 3. The batch mixer control device 3 has various roles, such as setting the amount of refractory particles and outputting various signals to operate the pump and solenoid valve 10. For example, as shown in FIG. 2, the batch mixer control device 3 outputs an operation signal for operating the pump 8. More specifically, the batch mixer control device 3 outputs a resin pump operation signal corresponding to the operation ON of the pump 8 for transporting the resin, and a hardener pump operation signal corresponding to the operation ON of the pump 8 for transporting the hardener. Also, as shown in FIG. 2, the batch mixer control device 3 outputs solenoid valve open signals (resin solenoid valve open signal and hardener solenoid valve open signal) related to the opening and closing of the solenoid valve 10.

[0036] Here, the operation of each pump 8 is controlled by the controller 21 by receiving a pump operation signal from the controller 21. Meanwhile, the opening and closing of each solenoid valve 10 is controlled by the batch mixer control device 3 during automatic operation described later. Note that the opening and closing of each solenoid valve 10 is controlled by the controller 21 during a calibration mode described later.

[0037] The batch mixer 2 also has an operation start button for starting automatic operation and an operation stop button for stopping automatic operation. The batch mixer 2 starts operation (automatic operation) when the operation start button is turned on. At this time, various signals are output from the batch mixer control device 3 to the controller 21 (see FIG. 6). These signals are received by the signal receiving and processing unit 39 of the controller 21.

[0038] As shown in FIG. 1, the sand hopper 4 is provided with a temperature sensor 5. The temperature sensor 5 detects the temperature (sand temperature) of the refractory particles in the sand hopper 4. A frame 6 is disposed below the batch mixer 2. A master model (not shown) is disposed within the frame 6. In other words, the frame 6 surrounds the master model. When the batch mixer 2 is in operation (automatic operation), materials are mixed within the batch mixer 2. When the automatic operation stops, the user pours the mold material from the batch mixer 2 into the frame 6, and then the frame 6 is removed and the master model (not shown) is extracted to form a mold.

[0039] (3. Configuration of the supply device) Next, each component constituting the supply device 12 will be described with reference to Fig. 1. As described above, the tank 7 and the pump 8 constitute the supply device 12 for supplying the liquid to the batch mixer 2. Each supply device 12 is provided with at least the pump 8 and a flow meter 9. For example, each of the three supply devices 12 of the mold molding apparatus 1 shown as an example in Fig. 1 is provided with a tank 7, a flow meter, an electromagnetic valve 10, and piping 11.

[0040] The solenoid valve 10 is provided in the batch mixer 2. Also, the batch mixer 2 may not be provided with the solenoid valve 10. Furthermore, the batch mixer 2 is provided with a pump (not shown) as one of its components, but in this embodiment, the pump of the batch mixer 2 is not used, and instead, the pump 8 provided as a component of the auto feeder 20 is used.

[0041] 1, the piping 11 constitutes a flow path R which serves as a transport path for the liquid in the supply device 12. Furthermore, each tank 7 is connected to the batch mixer 2 via the piping 11, and the tanks 7 and the batch mixer 2 are connected by the piping 11 to form a flow path R for the liquid. Furthermore, each pump 8 is provided so as to be interposed in the piping 11 which forms the flow path R, and the solenoid valve 10 is provided on the flow path R (piping 11) which continues to the batch mixer 2.

[0042] The tanks 7 are containers for storing liquid agents. Each tank 7 stores a different type of liquid agent. Specifically, tank 7A (resin tank) stores resin. Tank 7B (slow-hardening agent tank) stores a slow-hardening agent. Furthermore, tank 7C (fast-hardening agent tank) stores a fast-hardening agent.

[0043] The pump 8 is provided to transport the liquid to the batch mixer 2. As described above, in this embodiment, the pump 8 is provided as a component of the autofeeder 20. In this embodiment, the rotation speed of the pump 8 can be controlled by a frequency controlled by an inverter. Specifically, the pump 8 in this embodiment can control the flow rate by an operation frequency in the range of 0 Hz to 100 Hz by inverter control.

[0044] The flowmeter 9 is provided to measure the flow rate of the liquid agent flowing through the pipe 11. In this embodiment, the flowmeter 9 may be a flowmeter (4-20mA flowmeter) that outputs flow data as a predetermined current value (4-20mA) or a flowmeter (pulse flowmeter) that outputs a pulse signal once for each predetermined flow rate (for example, 1ml). In this embodiment, the 4-20mA flowmeter 9 is used in the case of a circulating supply device 12 described later. In the case of a non-circulating supply device 12 described later, the pulse flowmeter 9 is used. The flowmeter 9 is not limited to the above-mentioned type, and various types can be used. For example, the flowmeter 9 may be a flowmeter (0-5V flowmeter) that outputs flow data as a predetermined voltage value (0-5V).

[0045] The solenoid valve 10 is provided to control the opening and closing of the flow path R toward the batch mixer 2. As described above, the solenoid valve 10 is provided as a component of the batch mixer 2. The solenoid valve 10 may be a two-way valve that opens and closes the flow path from the tank 7 to the batch mixer 2, or a three-way valve that switches the destination of the liquid agent transported from the tank 7. For example, in the case of a circulating supply device 12 described later, the solenoid valve 10 of a three-way valve may be used (see FIG. 3). In addition, in the case of a non-circulating supply device 12 described later, the solenoid valve 10 of a two-way valve may be used (see FIG. 3). Note that, as described later, in the case of a non-circulating supply device 12, the solenoid valve 10 may not be provided.

[0046] (4. An example of the configuration of the supply device) Next, configuration examples of the supply device 12 will be described with reference to Figures 3 and 4. As shown in Figures 3 and 4, in the mold making apparatus 1 of this embodiment, various configurations can be adopted for the supply device 12.

[0047] 3, the supply device 12 may be one having a flow path R for returning the liquid to the tank 7 and capable of circulating the liquid (circulating supply device 12A), or one not having a flow path R for returning the liquid to the tank 7 and circulating it (non-circulating supply device 12B). That is, the multiple supply devices 12 controlled by the controller 21 may be one or both of the circulating supply device 12A and the non-circulating supply device 12B.

[0048] In the following description, among the supply devices 12, one having a flow path R for returning the liquid to the tank 7 and capable of circulating the liquid may be described as a "circulating supply device 12A" or simply as a "circulating type." Also, among the supply devices 12, one not having a flow path R for returning the liquid to the tank 7 and circulating it may be described as a "non-circulating supply device 12B" or simply as a "non-circulating type."

[0049] 3(a), in the circulating supply device 12A, a three-way valve (solenoid valve 10) is provided on a flow path R (piping 11) from the tank 7 to the batch mixer 2, and a flow path R (piping 11) heading toward the batch mixer 2 with the three-way valve (solenoid valve 10) as a branch point, and a flow path R (piping 11) returning the liquid to the tank 7 are provided. The circulating supply device 12A transports and circulates the liquid during normal operation, and controls the opening and closing of the solenoid valve 10 at the start and end of supplying the liquid to the batch mixer 2, making it possible to switch the flow path R for the liquid.

[0050] More specifically, in the circulating supply device 12A, the pump 8 is operated to transport the liquid regardless of whether the supply of the liquid to the batch mixer 2 is ON (during dispensing) or OFF (during circulation). Also, in the circulating supply device 12A, the solenoid valve 10 is OFF (the flow path to the batch mixer 2 is closed) during circulation (standby), and the solenoid valve 10 is ON (the flow path to the batch mixer 2 is open) during supply of the liquid to the batch mixer 2 (during dispensing).

[0051] That is, while the supply of the liquid to the batch mixer 2 is stopped (on standby), the circulating supply device 12A is configured to circulate the liquid from "tank 7 → pump 8 → flow meter 9 → three-way valve (solenoid valve 10) → tank 7" (see the dashed arrow in FIG. 3(a)). Also, in the circulating supply device 12A, while a signal is being received from the batch mixer 2 (during the cut-out time), the three-way valve (solenoid valve 10) is turned ON, and the flow path R of the liquid is switched to "tank 7 → pump 8 → flow meter 9 → three-way valve (solenoid valve 10) → batch mixer 2" (see the solid arrow in FIG. 3(a)).

[0052] 3(b) and (c), the non-circulating supply device 12B transports the liquid only when the liquid is supplied to the batch mixer 2. Also, as shown in Fig. 3(b) and (c), the non-circulating supply device 12B may or may not be provided with the solenoid valve 10. As shown in Fig. 3(c), in the non-circulating supply device 12B provided with the solenoid valve 10, a two-way valve (solenoid valve 10) is provided on the flow path R (piping 11) from the tank 7 to the batch mixer 2.

[0053] In the non-circulating supply device 12B illustrated in Fig. 3(b) (non-circulating supply device 12B not provided with the solenoid valve 10), the pump 8 is turned OFF while waiting to supply the liquid to the batch mixer 2. In the non-circulating supply device 12B not provided with the solenoid valve 10, the pump 8 is turned ON while a signal is being received from the batch mixer 2 (during the feed time), and the liquid is transported from "tank 7 → pump 8 → flow meter 9 → batch mixer 2" (see the solid arrow in Fig. 3(b)).

[0054] In the non-circulating supply device 12B (non-circulating supply device 12B provided with the solenoid valve 10) illustrated in Fig. 3(c), while waiting for the supply of the liquid to the batch mixer 2, both the pump 8 and the solenoid valve 10 are turned OFF, and the flow path R to the batch mixer 2 is closed. In addition, in the non-circulating supply device 12B illustrated in Fig. 3(c), when the supply of the liquid to the batch mixer 2 starts (when the signal is ON), both the pump 8 and the solenoid valve 10 are turned ON, and the flow path R to the batch mixer 2 is opened (see the solid arrow in Fig. 3(c)).

[0055] The autofeeder 20 is compatible with both the circulating feeder 12A and the non-circulating feeder 12B. More specifically, the autofeeder 20 is provided with a plurality of connection terminals (input ports) (not shown) for connecting external devices such as the flowmeter 9 and the solenoid valve 10. The controller 21 of the autofeeder 20 stores a program corresponding to the external terminals connected to the input ports. Therefore, the autofeeder 20 can easily switch between the circulating and non-circulating modes by replacing the connection terminals of the flowmeter 9 and the solenoid valve 10 with the corresponding input ports and executing a circulating / non-circulating mode switching setting in the controller 21.

[0056] As a result, the autofeeder 20 (controller 21) can control the liquid agent in response to various configurations of the supply device 12. More specifically, the autofeeder 20 (controller 21) can flexibly respond to changes in the configuration of the supply device 12, without the need to prepare a separate autofeeder, when the configuration of the supply device 12 is changed afterwards (for example, when the supply device 12 is switched from a non-circulating type to a circulating type). In particular, when a problem occurs such as the solenoid valve 10 being broken, the autofeeder 20 (controller 21) of this embodiment can flexibly respond to operations such as temporarily removing the solenoid valve 10 and switching from a circulating type to a non-circulating type. In other words, the controller 21 can flexibly respond to changes in the piping type (between a circulating type and a non-circulating type) without the need to change the sequence.

[0057] In addition, among the supply devices 12 controlled by the autofeeder 20, some may be non-circulating supply devices 12B and the others may be circulating supply devices 12A. For example, as illustrated in Fig. 4(a), among the three supply devices 12 controlled by the autofeeder 20, the supply device 12 for supplying the resin may be the circulating supply device 12A, and the supply device 12 for supplying the hardener may be the non-circulating supply device 12B. Conversely, among the three supply devices 12 controlled by the autofeeder 20, the supply device 12 for supplying the resin may be the non-circulating supply device 12B, and the supply device 12 for supplying the hardener may be the circulating supply device 12A.

[0058] Furthermore, all of the supply devices 12 to be controlled by the autofeeder 20 may be non-circulating supply devices 12B, or all of them may be non-circulating supply devices 12B. For example, as illustrated in Fig. 4(b), of the three supply devices 12 to be controlled by the autofeeder 20, both the supply device 12 for supplying the resin and the supply device 12 for supplying the hardener may be non-circulating supply devices 12B, or both the supply device 12 for supplying the resin and the supply device 12 for supplying the hardener may be circulating supply devices 12A.

[0059] Furthermore, in the mold making apparatus 1 shown as an example in Figure 1, an example is shown in which three supply devices 12 are provided, but as described above, the number of supply devices 12 may be two (see Figure 4 (c)). As with the above example, both of the two supply devices 12 may be circulating supply devices 12A, or both may be non-circulating supply devices 12B. Furthermore, one of the two supply devices 12 may be a circulating supply device 12A and the other a non-circulating supply device 12B.

[0060] (5. Auto Feeder Configuration)

[0061] Next, the components and functions of the auto feeder 20 will be described. The auto feeder 20 is used in the batch mixer 2. More specifically, the auto feeder 20 is used to control or manage the amount of liquid supplied to the batch mixer 2. The auto feeder 20 has various functions, such as receiving a signal from the batch mixer 2 to operate the pump 8 or adjusting the mixture of the slow-setting agent and the fast-setting agent.

[0062] In the following description, the time set (stored) in the batch mixer control device 3 as the time for supplying the liquid to the batch mixer 2 may be described as "cut-out time T1." Also, the time (signal reception time) read by the controller 21 of the auto-feeder 20 upon receiving a signal from the batch mixer control device 3 may be described as "cut-out time T2" ​​(see FIG. 6).

[0063] 1, auto feeder 20 is provided with controller 21 (control device), display device 25, and notification device 26. Auto feeder 20 exemplified in this embodiment accommodates pumps 8 inside a housing. Note that pumps 8 do not necessarily have to be accommodated inside the housing of auto feeder 20, and may be provided outside the housing of auto feeder 20 and connected to controller 21.

[0064] The controller 21 (control device) controls the supply of a plurality of types of liquids, including a resin and a hardener, to the batch mixer 2 using the respective supply devices 12 corresponding to these liquids. As shown in FIG. 1, the controller 21 (control device) has, as a hardware configuration, a CPU 22, a RAM 23, a ROM 24, a display device 25, an alarm device 26, and an I / F (not shown), each of which is connected via a bus. The controller 21 is also connected to the batch mixer 2, a pump 8, a flowmeter 9, a solenoid valve 10, and a temperature sensor 5. The controller 21 is also capable of communicating with a server 50.

[0065] The CPU 22 is a conventionally well-known computing means, and controls the overall operation of the controller 21. The RAM 23 functions as a working area when the CPU 22 processes information. The ROM 24 stores various programs and data. In this hardware configuration, the CPU 22 performs calculations according to a predetermined program, and the controller 21 is configured with functional blocks according to the loaded program (see FIG. 2). Each function of the controller 21 will be described later.

[0066] The display device 25 is a liquid crystal display that displays various information. The display device 25 of this embodiment also functions as a user interface that can be operated by the user selecting a displayed image (button). That is, the display device 25 of this embodiment is a display (touch panel) with a touch panel function, and has a function as an operation device in addition to a function as a display device. The display device 25 may not have a touch panel function. If the display device 25 does not have a touch panel function, it is preferable that the auto feeder 20 is provided with an operation unit.

[0067] In the autofeeder 20, various settings can be made by accepting user operations on the display device 25. For example, in the autofeeder 20, the user can select a mode such as "normal operation mode" or "calibration mode" by touching and selecting button images displayed on the display device 25. In addition, in the autofeeder 20, the target amount (set amount) of each liquid agent per batch can be set by operating the display device 25. Specifically, in the autofeeder 20, the target amount per batch can be set by inputting the amount of sand, the amount of hardener to be added, and the amount of resin to be added into the display device 25.

[0068] The notification device 26 is for notifying various kinds of information. In the present embodiment, the notification device 26 is configured with a lamp, a buzzer, etc. The notification device 26 issues an alarm sound (alert) when the supply amount of the liquid agent is not within a predetermined range.

[0069] (6. Controller Function Blocks) Next, functions of the controller 21 (control device) will be described with reference to Fig. 2. As described above, the CPU 22 performs calculations according to a predetermined program, and functional blocks corresponding to the loaded program are configured in the controller 21. Note that the processes and operations executed by the controller 21 can be replaced with programs or control methods.

[0070] Specifically, as shown in FIG. 2, the controller 21 functions as a flow rate measurement unit 30, a supply amount calculation unit 31, an error determination unit 32, an alarm processing unit 33, a delay timer activation unit 34, a pump constant calculation unit 35, a pump constant setting unit 36, a pump operating frequency setting unit 37, a hardener compounding ratio calculation unit 38, a signal reception processing unit 39, a setting acceptance processing unit 40, a cut-out time setting unit 41, and the like, by the CPU 22 executing a program.

[0071] The flow rate measuring unit 30 measures the flow rate of the liquid by a predetermined method. For example, the flow rate measuring unit 30 measures the instantaneous flow rate of the liquid transported by the circulating supply device 12A and the cumulative number of instantaneous flow rates during a predetermined time (during the cut-out time T2). The flow rate measuring unit 30 also measures the number of pulses output from the flowmeter 9 during a predetermined time for the liquid transported by the non-circulating supply device 12B. To explain in more detail, the flow rate measuring unit 30 measures the number of pulses for the liquid transported by the non-circulating supply device 12B over a specific time period from the start of the cut-out time T2 to the end of the delay timer time after the cut-out time T2 (specific timing).

[0072] The supply amount calculation unit 31 calculates the supply amount of the liquid supplied per batch using the flow rate measured during a predetermined time. For example, the supply amount calculation unit 31 calculates the supply amount of the liquid supplied per batch for the liquid transported by the circulating supply device 12A using the instantaneous flow rate of the liquid, the integrated number of instantaneous flow rates, and the cut-out time T2. The supply amount calculation unit 31 also calculates the supply amount of the liquid supplied per batch for the liquid transported by the non-circulating supply device 12B using the pulse number. More specifically, the supply amount calculation unit 31 calculates the supply amount of the liquid supplied per batch for the liquid transported by the non-circulating supply device 12B using the pulse number during a specific time measured by the flow rate measurement unit 30.

[0073] The error determination unit 32 calculates the error between a predetermined target amount of the liquid per batch and the supply amount of the liquid per batch, and determines whether the error exceeds a threshold value. The error value (threshold value) to be determined by the error determination unit 32 may be a predetermined value, or may be set by a user operation.

[0074] The notification processing unit 33 performs processing for notifying various information. For example, the notification processing unit 33 performs processing for transmitting a predetermined command to the notification device 26 in order to cause the notification device 26 to display the flow rate measured by the flow rate measuring unit 30. Furthermore, when the error determining unit 32 determines that the error between the target amount and the supply amount exceeds a threshold, the notification processing unit 33 performs processing for causing the notification device 26 to execute a notification (for example, transmitting a corresponding command to the notification device 26). Furthermore, when an abnormality occurs in the flow rate during circulation (standby), the notification processing unit 33 performs processing for causing the notification device 26 to execute a notification.

[0075] The delay timer initiation unit 34 performs a process of initiating a delay timer. Specifically, the delay timer initiation unit 34 performs a process of setting a time related to the delay timer in a delay timer counter provided in the controller 21 and performing subtraction. Note that the management of the time related to the delay timer may be a subtraction method (count down) or an addition method (count up).

[0076] The pump constant calculation unit 35 calculates a pump constant indicating the performance of the pump. Specifically, the pump constant calculation unit 35 calculates a pump constant, which is a parameter indicating the relationship between the operation frequency and the discharge amount, by using the discharge amount of the liquid agent when the liquid agent is discharged for a predetermined time (e.g., cut-out time T2) and the operation frequency of the pump.

[0077] The pump constant setting unit 36 ​​sets the pump constant. For example, the pump constant setting unit 36 ​​stores the pump constant calculated by the pump constant calculation unit 35 as a new pump constant.

[0078] The pump operation frequency setting unit 37 controls the operation frequency of the pump 8 based on various information. For example, the pump operation frequency setting unit 37 controls the operation frequency of the pump 8 based on information such as the compounding ratio of the liquid, a set pump constant, and a target amount of the liquid.

[0079] The hardener compounding ratio calculation unit 38 calculates the compounding ratio of the slow-hardening agent and the fast-hardening agent based on the temperature information acquired from the temperature sensor 5.

[0080] The flow rates of the retarder and fast hardener are controlled using the corresponding flowmeters 9 and pumps 8, respectively, but the controller 21 controls the amount of hardener (the total amount of retarder and fast hardener) to be constant. That is, the controller 21 performs various calculations and controls so that the amount of hardener (the total amount of the liquid agent, which is the total amount of the retarder and fast hardener supply) is constant, although the blending ratio of the retarder and fast hardener is changed according to the sand temperature. For example, the controller 21 calculates the total value of the retarder and fast hardener as the "amount of hardener" in the supply amount calculation process, error judgment process, notification process, and hardener blending ratio calculation process, which will be described later.

[0081] The signal receiving and processing unit 39 receives various signals from the batch mixer control device 3 and controls the start of operation of the pump 8 .

[0082] The setting reception processing unit 40 receives a user's operation (input) on the display device 25, and performs processing corresponding to the operation.

[0083] The cut-out time setting unit 41 receives various signals from the batch mixer control device 3 and measures the signal reception time when the cut-out time is initially set or when the cut-out time is set in the calibration mode (when the cut-out time is initially set or when the cut-out time is set by manual operation in the calibration mode), and stores the signal reception time as the "cut-out time T2."

[0084] (7. Difference between batch mixer and continuous mixer) Next, the differences between the continuous mixer 130 and the batch mixer 2 will be described with reference to FIG.

[0085] The continuous mixer 130 is capable of continuously manufacturing a mold by continuously supplying sand and liquid. That is, the continuous mixer 130 continues to supply refractory particles and liquid until the automatic operation state is released. The continuous mixer 130 also continuously outputs various signals related to the resin and hardener (pump operation signal and solenoid valve open signal). That is, the continuous mixer 130 does not have a set time for feeding the liquid, and the liquid is continuously supplied while the continuous mixer 130 is operating.

[0086] On the other hand, when the operation start button of the batch mixer 2 is turned on, a predetermined amount of refractory particles is put into the batch mixer 2, and various signals are output for a set time (cut-out time T1). Note that both the continuous mixer 130 and the batch mixer 2 are the same in that various signals are transmitted by the mixer.

[0087] Here, in the continuous mixer 130, the target amount and the feed time for each process are not determined. In other words, in the continuous mixer 130, there is no concept of "feed time of the liquid agent". On the other hand, in the batch mixer 2, the feed time T1 for each process is determined. Therefore, as will be described later in detail, in the flow rate management and supply amount control of the auto feeder 20 used in the batch mixer 2, it is a challenge to accurately capture the feed time T1.

[0088] (8. Roles of Batch Mixers and Auto Feeder) Next, the role of the batch mixer 2 and the role of the auto feeder 20 will be explained. The batch mixer 2 is basically capable of controlling ON / OFF of the supply of the liquid even without the auto feeder 20. Specifically, the batch mixer 2 is equipped with a solenoid valve 10 and a pump (not shown) as its configuration, and by driving the pump to supply the liquid, the batch mixer 2 alone can complete the molding of a mold, including the supply of the liquid. In other words, although it is difficult to "manage the flow rate" of the liquid by the batch mixer 2 alone, the supply of the liquid itself is possible.

[0089] On the other hand, the auto feeder 20 has the following functions (1) to (3): (1) receiving various signals (resin pump operation signal and hardener pump operation signal) from the batch mixer 2 and operating the pump 8 that transports the liquid, (2) setting and controlling the amount of liquid supplied, and (3) acquiring the temperature of the sand and calculating the mixture of slow-hardening liquid and fast-hardening liquid in the hardener and the discharge amount of the pump 8 (inverter frequency).

[0090] In this way, the batch mixer 2 can complete molding operations including supplying liquid even without the auto feeder 20. On the other hand, although the auto feeder 20 can control the amount of liquid supplied, it cannot complete molding operations including sand charging, liquid supply, kneading operations, etc. by itself (the auto feeder 20 alone). Therefore, it can be said that the auto feeder 20 is a device accompanying the batch mixer 2 (a device that assists the batch mixer 2). In this way, the auto feeder 20 performs controls accompanying the operation of the batch mixer 2, such as flow rate management and changing the hardening speed, which are difficult to perform with the batch mixer 2.

[0091] The autofeeder 20 of this embodiment is provided with a pump (pump 8) separate from the pump provided in the batch mixer 2. That is, the batch mixer 2 is also provided with a pump, but the autofeeder 20 is provided with a pump 8 that can be controlled by an operation frequency. Also, the autofeeder 20 can operate the pump 8 by receiving a pump operation signal from the batch mixer 2, as described below.

[0092] Here, in this embodiment, an example in which the batch mixer 2 is provided with the solenoid valve 10 has been shown, but many batch mixers 2 provided in actual sites are not provided with the solenoid valve 10. Furthermore, when the batch mixer 2 is not provided with the solenoid valve 10, it is rare to take the trouble to additionally install the solenoid valve 10, for reasons such as avoiding the complexity of control. In order to accommodate various patterns such as the presence or absence of the solenoid valve 10 of the batch mixer 2, the auto feeder 20 is capable of receiving all signals, including the resin pump operation signal, the resin solenoid valve open signal, the hardener pump operation signal, and the hardener solenoid valve open signal.

[0093] Even when a batch mixer 2 equipped with a solenoid valve 10 is used, the advantage of using the solenoid valve 10 (suppression of dripping, which will be described later) and the risk of the solenoid valve 10 breaking are taken into consideration, and as a result, operation without using the solenoid valve 10 is performed at many sites. Specifically, in the past, many batch mixers 2 were equipped with a solenoid valve 10 (such as a two-way valve), but two-way valves are prone to breaking and can easily cause problems. For example, if the two-way valve stops working, the system will operate in a blocked state, which can cause various problems.

[0094] For this reason, in recent years, even when a solenoid valve is provided in the batch mixer 2, the solenoid valve is often removed in order to avoid risks. Also, in order to accommodate such operations, many batch mixers 2 that are not provided with the solenoid valve 10 are being provided. As a result, batch mixers 2 that are not provided with the solenoid valve 10 are often used in recent work sites. Following this, there is an increasing need for the auto feeder 20 used in the batch mixer 2 to accommodate situations in which the solenoid valve 10 is not provided.

[0095] (9. Flow rate management in batch mixers, issues in improving accuracy of supply volume) Here, conventionally, when molding a mold using a batch mixer 2, it has been an issue to reduce the error between the target amount of liquid per batch and the amount of liquid actually supplied.

[0096] In response to such problems, the inventor of the present invention considered applying the configuration of the continuous mixer 130 to an autofeeder used in the batch mixer 2. However, the continuous mixer 130 is often provided with a solenoid valve 10 due to its characteristic of constantly supplying the liquid, whereas the batch mixer 2 is often not provided with a solenoid valve 10. Even if the batch mixer 2 is provided with a solenoid valve 10, it is often not used. Furthermore, the batch mixer 2 not provided with the solenoid valve 10 must be of a non-circulating type, and must deal with a situation in which the liquid is not circulating (a situation in which the flow rate is not moving).

[0097] As described above, it is the batch mixer 2 that mixes the sand, and the auto feeder 20 must operate in accordance with the control of the molding process of the batch mixer 2. Therefore, the setting of the liquid feed time T2 in the auto feeder 20 (controller 21) must follow the setting of the liquid feed time T1 in the batch mixer 2.

[0098] Due to differences in characteristics between the continuous mixer 130 and the batch mixer 2, the presence or absence of the concept of "feed-out time", etc., it was difficult to immediately apply the supply amount control of the continuous mixer 130 to the supply amount control of the batch mixer 2. The inventors of the present invention therefore conducted extensive research into a method for improving the supply amount error in the batch mixer 2 while dealing with the characteristics of the batch mixer 2, and came to the knowledge that these problems could be solved by accurately grasping the feed-out time.

[0099] Here, the conventional setting (understanding) of the cut-out time in the batch mixer 2 will be explained. The timer relay (not shown) provided in the batch mixer 2 can be of a digital type with a built-in PLC or an analog type. In the case of a digital type timer relay, precise time measurement in units of 0.1 seconds is often set, and the measured time is displayed digitally, making it easy to understand the cut-out time T1 of the batch mixer 2.

[0100] On the other hand, with an analog timer relay, it is difficult to display time as precisely as with a digital timer relay, and the displayed time is displayed in an analog manner (the time is displayed by the time indicated by a needle on a display panel). Therefore, when trying to grasp the cut-out time T1 based on the display of an analog timer relay provided in the batch mixer 2, even if the cut-out time T1 is actually "8.3 seconds", the needle may indicate a value in the vicinity of "8 seconds", making it difficult to grasp the accurate cut-out time T1 (for example, in units of 0.1 seconds). In this way, with an analog timer relay, errors are likely to occur with respect to the accurate cut-out time.

[0101] Furthermore, in batch mixers 2 that have been in operation for many years, the display portion of the analog timer relay may have become discolored by resin or oil, making it difficult to grasp the time (or even to see it), or the timer relay may have deteriorated, reducing the reliability of the displayed time.

[0102] To solve the above problem, it would be better to use a batch mixer 2 that uses a digital timer relay, but in many cases, such a solution cannot be implemented immediately. Specifically, the batch mixer 2 is not easily broken, and even decades after its introduction, batch mixers 2 equipped with analog timer relays are still in operation. In addition, if the timer relay of the batch mixer 2 is digital, special equipment is required to change the setting of the cut-out time, making it difficult to use in the field. Furthermore, in actual field situations, regardless of whether the timer relay is analog or digital, the user may roughly grasp the cut-out time T1 displayed on the timer relay of the batch mixer 2 (for example, even if the display shows "8.3 seconds," the user may enter "8.0 seconds").

[0103] In addition, in actual work sites, in order to improve the supply accuracy of the liquid using a conventional auto feeder, the batch mixer 2 is test run to measure the discharge amount of the liquid, and the pump operation frequency of the auto feeder is manually reset based on the experience of an experienced worker. However, even if the time (e.g., 8.0 seconds) displayed as the batch mixer 2 cut-out time T1 is trusted and the cut-out time T2 is set to "8.0 seconds" on the auto feeder, there are many cases where there is an error, such as the actual batch mixer 2 cut-out time T1 (actual supply time) being "8.3 seconds". In addition, if calculations are performed using that time with the error, the calculation of the pump frequency will be distorted, and as a result, there is a problem that even if the user resets (recalculates) the pump constants, etc., the supply amount error is not improved much.

[0104] As a result of intensive research by the inventor of the present invention, the above-mentioned various circumstances were clarified, and it was found that these circumstances were the causes of errors in the supply amount of the liquid drug, and the actual feed time T1 was not accurately grasped. Furthermore, the inventor of the present invention has come to the conviction that it is possible to improve the accuracy of the supply amount (reduce errors) by minimizing the error between the "feed time T1" of the batch mixer 2 and the "feed time T2" ​​of the autofeeder 20 (controller 21).

[0105] Furthermore, as a result of the inventors of the present invention earnestly studying ways to improve the accuracy of the cut-out time T2, they have come to the knowledge that the accuracy of the cut-out time T2 can be improved by reading the pump operation signal of the batch mixer 2 in the auto feeder 20 (controller 21) and storing that time as the "cut-out time T2." That is, by storing the cut-out time T2 based on the output time of the pump operation signal of the batch mixer 2, the auto feeder 20 (controller 21) can minimize the error between the actual cut-out time T1 of the batch mixer 2 and the cut-out time T2 of the auto feeder 20 (controller 21) compared to when a person visually checks the timer relay of the batch mixer 2 and inputs it to the auto feeder 20, and can also suppress human error compared to when a person inputs it.

[0106] (10. Various signals and cut-out times output from the batch mixer control device) Next, with reference to FIG. 6, the relationship between the output timing of various signals output from the batch mixer control device 3 and the cut-out time T2 will be described.

[0107] The controller 21 of this embodiment can read the accurate cut-out time by capturing the reception times of various signals output from the batch mixer control device 3. As a result, the controller 21 of this embodiment realizes the above-mentioned improvement in the accuracy of calculation of the supply amount of the liquid agent, improvement in the accuracy of error determination, improvement in the accuracy of calculation of the pump constant, etc.

[0108] The reading and setting of the cutting time T2 of each liquid agent (see the cutting time setting process in FIG. 17) can be performed by manually operating the batch mixer 2 at the time of initial setting of the controller 21 (such as when the autofeeder 20 is delivered). Specifically, each component (pump, solenoid valve, etc.) of the batch mixer 2 is individually operated (individual operation), the controller 21 reads the output time (cut-out time T1) of various signals output from the batch mixer control device 3, and the controller 21 stores the time as the "cut-out time T2", thereby performing the initial setting of the cut-out time T2. The controller 21 can also execute the cut-out time setting process in a calibration mode, which will be described later (the cut-out time T2 can be re-read and reset). The controller 21 also uses the stored "cut-out time T2" ​​to calculate the supply amount of the liquid agent per batch and the pump constant.

[0109] As shown in Fig. 6, the batch mixer control device 3 outputs both or one of a pump operation signal and a solenoid valve open signal depending on the configuration of the supply device 12, such as the presence or absence of a solenoid valve 10. The signal output start timing is when the automatic operation of the batch mixer 2 starts, except for the pump operation signal in the case of the circulation type. In the case of the circulation type, the pump operation signal is ON regardless of whether the supply of the liquid agent is ON or OFF. In addition, when a predetermined feed time T1 (set feed time) has elapsed since the start of the automatic operation, the batch mixer control device 3 automatically cancels the operation and stops outputting the predetermined signal.

[0110] 6, the relationship between the signal output from the batch mixer control device 3 and the operation of the pump 8 by the autofeeder 20 (controller 21) will be described for each of the patterns of the circulation type (pattern A), the non-circulation type with the solenoid valve 10 (pattern B-1), and the non-circulation type without the solenoid valve 10 (pattern B-2). Note that in FIG. 6, the case where the object to be conveyed is a resin will be described as an example, but the same signals (hardener pump operation signal and hardener solenoid valve open signal) are also output for the hardener depending on whether the system is a circulation type or not, and whether the solenoid valve 10 is present in the non-circulation type.

[0111] The operation of the pump 8 (ON / OFF of the pump 8) is controlled by the controller 21, but the opening and closing of the solenoid valve 10 is controlled by the batch mixer control device 3. In the case of a non-circulation type, the controller 21 operates the pump 8 while signals (pump operation signal and solenoid valve open signal) are being output from the batch mixer control device 3 (during the feed time T1).

[0112] Here, the ON / OFF and rotation speed (operation frequency) of each pump 8 are controlled by the controller 21. Meanwhile, as described above, the control of each solenoid valve 10 during automatic operation is performed by the batch mixer control device 3. Therefore, when the supply device 12 is of the circulation type, the controller 21 executes flow rate control of the liquid during feeding, but does not control ON / OFF of the supply of the liquid itself. For example, as shown in FIG. 6(a), in the case of the circulation type, the controller 21 operates the pump 8 at all times, and the supply of the liquid to the batch mixer 2 is switched ON / OFF by switching the flow path R of the solenoid valve 10 under the control of the batch mixer control device 3. In addition, in the case of the circulation type, the controller 21 grasps the start of the liquid supply by the ON of the solenoid valve open signal, and starts measuring the flow rate of the liquid and accumulating the number of measurements.

[0113] On the other hand, in the case of the non-circulation type, when the controller 21 receives a signal from the batch mixer control device 3 as a trigger for starting the dispensing of the liquid, the controller 21 operates the pump 8 (resin pump) corresponding to the liquid for the dispensing time T2 of the corresponding liquid from the reception of the signal, and controls the supply of the liquid. That is, in the case of the non-circulation type, the controller 21 can be said to control the ON / OFF supply of the liquid in addition to controlling the flow rate of the liquid during dispensing.

[0114] For example, as shown in Fig. 6(b), in the case where the resin supply device 12 is a non-circulation type equipped with an electromagnetic valve 10, when the controller 21 receives a resin pump operation signal and a resin opening / closing signal from the batch mixer control device 3, it operates the corresponding pump 8 (resin pump) upon receiving these signals to start feeding (supplying) of the resin. Also, when the resin pump operation signal output from the batch mixer control device 3 stops (when the signal turns OFF), the controller 21 stops the operation of the pump 8 (resin pump) and ends feeding (supply) of the resin.

[0115] 6(c), in the case where the resin supply device 12 is a non-circulation type not equipped with the solenoid valve 10, when the controller 21 receives a resin pump operation signal from the batch mixer control device 3, the controller 21 operates the corresponding pump 8 (resin pump) upon receiving the signal to start feeding (supply) of the resin. When the resin pump operation signal output from the batch mixer control device 3 stops (when the signal turns OFF), the controller 21 stops the operation of the pump 8 and ends feeding (supply) of the resin.

[0116] In this way, in the case of the circulation type (pattern A), the controller 21 grasps the start of supply of the liquid agent by starting to receive the solenoid valve open signal output from the batch mixer control device 3. Also, in the case of the non-circulation type and the solenoid valve 10 (pattern B-1), the controller 21 starts to operate the pump 8 to start supplying the liquid agent by starting to receive the pump operation signal and the solenoid valve open signal output from the batch mixer control device 3. Furthermore, in the case of the non-circulation type and the solenoid valve 10 not being present (pattern B-2), the controller 21 starts to operate the pump 8 to start supplying the liquid agent by starting to receive the pump operation signal output from the batch mixer control device 3. That is, the controller 21 starts measuring the flow rate of the liquid agent by receiving a signal from the batch mixer 2.

[0117] Furthermore, the controller 21 controls the stop of the supply of the liquid or recognizes the stop of the supply of the liquid by turning OFF the signal output from the batch mixer control device 3. That is, in the controller 21, the trigger for starting the measurement of the flow rate of the liquid is the start of reception of a signal from the batch mixer control device 3, and the trigger for ending the measurement of the flow rate of the liquid is the end of reception of a signal from the batch mixer control device 3.

[0118] Next, the feed-out time T2 stored in the controller 21 will be described with reference to FIG. 7. As described above, the controller 21 reads the feed-out time T1 output from the batch mixer control device 3 and stores the time as the "feed-out time T2". The controller 21 also uses the feed-out time T2 to calculate the amount of liquid agent supplied per batch and to calculate the pump constant. The feed-out times T2 (resin feed-out time T2a and hardener feed-out time T2b) can be read by, for example, performing individual operation of the batch mixer 2 (manual operation in which the components such as the pump 8 and the solenoid valve 10 are individually operated).

[0119] 7, the controller 21 stores the time from the start of output to the end of output of the signal for which the cut-out time is to be read as "cut-out time T2." For example, if the cut-out time is to be read for a resin, the controller reads the output time of the resin pump operation signal or the resin solenoid valve open signal, and stores that time as "resin cut-out time T2a." If the cut-out time is to be read for a hardener, the controller reads the output time of the hardener pump operation signal or the hardener solenoid valve open signal, and stores that time as "hardener cut-out time T2b."

[0120] In this way, the controller 21 receives various signals output from the batch mixer control device 3, and stores the cut-out time T2 of the resin and the hardener based on the reception time (cut-out time T1) of these signals. In addition, the reception time (cut-out time T1) of the signal output from the batch mixer control device 3 and the time (cut-out time T2) stored by the controller 21 as the cut-out time are almost the same. The controller 21 can read the reception time (cut-out time T1) of the signal output from the batch mixer control device 3 in the time reading unit of the timer relay (every 0.1 seconds in this embodiment). Therefore, the controller 21 can improve the reading accuracy of the cut-out time T1 of the batch mixer 2.

[0121] In the case of the hardener, the controller 21 starts supplying two types of liquid agents, a slow hardening agent and a fast hardening agent, by receiving one or both of the hardener operation pump and hardener solenoid valve open signals from the batch mixer control device 3. That is, the supply start timing and the feed time of the slow hardening agent and the fast hardening agent are the same.

[0122] 7, when the controller 21 receives a signal (a signal that turns on the dispensing of the liquid) that triggers the start of dispensing of any one of the multiple liquid formulations, the controller 21 determines that "automatic operation has started." Furthermore, when the dispensing of all the multiple liquid formulations is completed, the controller 21 determines that "automatic operation has ended." In other words, the controller 21 determines the time from the reception of a signal that triggers the dispensing of any one of the liquid formulations to the end of dispensing of all the liquid formulations (automatic operation time T3) as one process.

[0123] In this embodiment, the output time of the resin pump operation signal (resin feed time T1a) and the output time of the hardener pump operation signal (hardener feed time T1b) are different times as shown in Fig. 7. Also, as shown in Fig. 7, in this embodiment, the start of resin feed and the start of hardener feed are different timings (resin feed starts first and hardener feed starts later).

[0124] The controller 21 can change the resin feed-out time, the hardener feed-out time, and the timing of the start of resin feed-out and the start of hardener feed-out according to the settings on the batch mixer 2 side or according to the user's operation. Therefore, the controller 21 can set the resin feed-out time T2a and the hardener feed-out time T2b to be the same, or set the start of resin feed-out and the start of hardener feed-out to be the same timing.

[0125] In this way, the controller 21 performs various controls during automatic operation by receiving various signals from the batch mixer control device 3. As described above, the auto feeder 20 is a device associated with the batch mixer 2, and if the auto feeder 20 (controller 21) intervenes in the control of the batch mixer control device 3, such as changing the supply time of the mold making process, it may affect the overall control of the mold making process. For this reason, the auto feeder 20 (controller 21) rarely outputs a signal to command the batch mixer 2 to operate, etc.

[0126] In the following description, the period during the feed-out time T2 may be simply described as "during the feed-out time" or "during feed-out". Furthermore, during the feed-out time T2, the liquid agent is supplied to the batch mixer 2. Therefore, the period during feed-out may be simply described as "supply ON".

[0127] (11. Autofeeder operation mode) Next, each mode that can be executed by the auto feeder 20 will be described. The auto feeder 20 has a plurality of operation modes. Specifically, the auto feeder 20 has at least two operation modes, a "normal operation mode" and a "calibration mode". Although the auto feeder 20 also has a plurality of other operation modes, such as a manual mode, the normal operation mode and the calibration mode will be described below.

[0128] The screen of the display device 25 is provided with a plurality of mode selection buttons (not shown) for selecting an operation mode. For example, the screen of the display device 25 can display a normal operation mode selection button, a weighing mode selection button, etc. (not shown). In addition, in the autofeeder 20, the user can select and confirm an operation mode by performing an operation such as touching a mode selection button, thereby switching the operation mode.

[0129] For example, when the user touches the normal operation mode selection button to select and confirm the normal operation mode, the controller 21 executes control in the normal operation mode. The normal operation mode is released when another operation mode is selected and confirmed by performing an operation such as touching another operation mode button (such as a calibration mode button) displayed on the display device 25. When the user touches the calibration mode selection button to select and confirm the calibration mode, the controller 21 executes control in the calibration mode.

[0130] In addition to the operations on the display device 25 described above, the auto feeder 20 is provided with a number of operation buttons and switches (not shown), and the user can select and switch operating modes by pressing these buttons or switches.

[0131] The "normal operation mode" refers to a state in which the auto feeder 20 waits for the batch mixer 2 to start operating, and a state in which the auto feeder 20 supplies the liquid in conjunction with the operation of the batch mixer 2. In the normal operation mode, the controller 21 executes normal operation control, which will be described later, such as waiting for a signal to be received from the batch mixer control device 3 and controlling the flow rate of the liquid. In the following description, the state in which the normal operation mode is selected may be simply described as "normal operation".

[0132] Also, during normal operation, the state in which the controller 21 is waiting to receive a signal from the batch mixer control device 3 may be described simply as "on standby" or "on standby state." Furthermore, if the supply device 12 is of a circulation type, the state in which the liquid agent is not supplied to the batch mixer 2 during standby but is circulated back to the tank 7 may be described simply as "circulating."

[0133] (12. Control during normal operation mode in case of circulation type) Next, the control during the normal operation mode (normal operation) executed by the controller 21 will be described with reference to Figures 8 to 9. First, the control during normal operation executed by the controller 21 when the supply device 12 is of the circulation type will be described with reference to Figures 8 to 9. Figure 8 is a timing chart showing the control during normal operation executed by the controller 21 in the case of the circulation type in a chronological order.

[0134] The controller 21 stores the amount of resin to be added to the fire-resistant particles, the amount of hardener to be added, the compounding ratio, and the like, by receiving a user's operation on the display device 25. Note that this information is set (stored in the controller 21) by the setting reception processing unit 40 (controller 21) performing a reception process.

[0135] The controller 21 is capable of selecting or changing the flow rate measurement method depending on whether the supply device 12 is of the circulating type or the non-circulating type. In addition, in the process of calculating the supply amount of the liquid agent inputted per batch (supply amount calculation process), the controller 21 executes a part of different control depending on whether the supply device 12 is of the circulating type or the non-circulating type (see Figs. 9 and 12). In other words, the controller 21 executes a process (process during normal operation for the circulating type or process during normal operation for the non-circulating type) corresponding to the supply device 12 of each liquid agent for the control during normal operation of each liquid agent.

[0136] Furthermore, the controller 21 executes a plurality of normal operation processes corresponding to each liquid. For example, when all of the liquids, ie, the resin, the slow-hardening agent, and the fast-hardening agent, are transported by the circulating supply device 12A, the controller 21 executes a circulating normal operation process for the resin, a circulating normal operation process for the slow-hardening agent, and a circulating normal operation process for the fast-hardening agent.

[0137] In addition, when all of the liquid materials, namely the resin, the slow-hardening agent, and the fast-hardening agent, are transported by the non-circulating supply device 12B, the controller 21 performs non-circulating normal operation processing for the resin, non-circulating normal operation processing for the slow-hardening agent, and non-circulating normal operation processing for the fast-hardening agent.

[0138] Furthermore, in the case where the resin is transported by the circulating supply device 12A and the slow-hardening agent and the fast-hardening agent are transported by the non-circulating supply device 12B, the controller 21 performs a circulating normal operation process for the resin, a non-circulating normal operation process for the slow-hardening agent, and a non-circulating normal operation process for the fast-hardening agent.

[0139] As shown in Fig. 8, when the normal operation mode is turned on, the controller 21 performs a circulatory standby process such as measuring the instantaneous flow rate of the liquid to be transported by the circulatory supply device 12A. If the liquid is a hardener, the controller 21 performs a circulatory standby process, such as measuring the instantaneous flow rate and controlling the flow rate, as well as calculating the compounding ratio of the hardener according to the sand temperature.

[0140] 8, when the liquid to be transported by the circulating supply device 12A starts to be dispensed (when a signal that triggers the start of supply of the liquid is received), the controller 21 performs circulating-type dispense processing, such as measuring the instantaneous flow rate of the liquid, integrating the instantaneous flow rate, and controlling the flow rate. Also, when the liquid is a hardener, the controller 21 calculates the compounding ratio of the hardener according to the sand temperature in addition to measuring the instantaneous flow rate and integrating the instantaneous flow rate.

[0141] 8, the controller 21 performs a circulatory supply amount calculation process, an error determination process, and a notification process after the end of the delivery time of the liquid agent to be transported by the circulatory supply device 12A. These processes will be described in detail later.

[0142] (13. Circulation type normal operation process) Next, a process during normal operation for the circulating system, which is executed by the controller 21 for the liquid agent to be transported by the circulating supply device 12A, will be described with reference to Fig. 9. Fig. 9 is a flow chart showing the process during normal operation for the circulating system.

[0143] In step 60 (circulation type standby processing), the controller 21 performs processing to measure the instantaneous flow rate and control the flow rate of the liquid. In this embodiment, the controller 21 acquires the instantaneous flow rate output from the flowmeter 9 at any time and stores the acquired instantaneous flow rate. The controller 21 also controls the flow rate of the liquid by controlling the frequency of the pump 8. In addition, in the circulation type standby processing, if the value falls outside a predetermined range continuously for a predetermined time or more (e.g., 5 seconds) (if the value remains abnormal for a predetermined time or more), the controller 21 performs processing to notify the abnormality (output an alert). When the processing of step 60 is completed, the controller 21 moves the processing to step 61.

[0144] When the liquid agent to be controlled is a hardener, the controller 21 (hardener compounding ratio calculation unit 38) performs the above-mentioned instantaneous flow rate measurement and flow rate control, as well as a process of calculating the compounding ratio of the slow-hardening agent and the fast-hardening agent according to the temperature (temperature of the sand) obtained from the temperature sensor 5. That is, even while waiting for the start of hardener dispensing (on standby), the controller 21 always calculates the compounding ratio of the hardener according to the sand temperature to prepare for the start of hardener dispensing.

[0145] In step 61, the controller 21 (signal receiving processor 39) performs a process of determining whether or not dispensing has started. As described above, the determination of whether or not dispensing has started is made based on whether or not a predetermined signal (a signal that triggers dispensing of the liquid agent) output from the batch mixer control device 3 has been received (whether or not the signal has turned ON). If it is determined that dispensing has started (step 61=YES), the controller 21 proceeds to the process of step 62. On the other hand, if it is determined that dispensing has not started (step 61=NO), the controller 21 proceeds to the process of step 60. That is, the controller 21 repeats the circulatory standby process until dispensing has started.

[0146] In step 62 (circulation type feeding process, flow rate measurement step), the controller 21 (flow rate measurement unit 30) performs processes of measuring the instantaneous flow rate, integrating the instantaneous flow rate, counting the number of times the instantaneous flow rate has been integrated, and controlling the flow rate of the liquid. In this embodiment, the controller 21 acquires the instantaneous flow rate output from the flowmeter 9 every 0.5 seconds, integrates and stores the acquired instantaneous flow rate. The controller 21 (flow rate measurement unit 30) also counts the number of times the instantaneous flow rate has been integrated.

[0147] When the liquid agent to be controlled is a hardener, the controller 21 (hardener blending ratio calculation unit 38) calculates the blending ratio of the slow-hardening agent and the fast-hardening agent according to the temperature (sand temperature) acquired from the temperature sensor 5. In addition, the controller 21 (pump operation frequency setting unit 37) controls the flow rate and blending ratio of the hardener by controlling the operation frequency of the pump 8 so as to achieve that blending ratio.

[0148] Here, the measurement of the instantaneous flow rate will be described in more detail. As described above, in this embodiment, the controller 21 measures the instantaneous flow rate (g / min) during circulation using the 4-20 mA flowmeter 9. In the case of the circulation type, the instantaneous flow rate can be read at a frequency of, for example, "once / 0.5 s". As described above, the controller 21 acquires flow rate data from the flowmeter 9 during standby, monitors (stores) the flow rate of the circulating liquid, and notifies the abnormality when an abnormal value is detected for a predetermined period of time or more (when a flow rate abnormality occurs). In addition, during circulation (standby), the controller 21 displays the current flow rate as an instantaneous flow rate measurement value in real time on the display device 25. Note that, when only the supply device 12 that supplies the resin is of the circulation type, the set flow rate during circulation of the hardener is set to "0" (=no flow rate is set during automatic operation standby).

[0149] In step 63, the controller 21 performs a process to determine whether or not dispensing has finished. The determination of whether or not dispensing has finished is performed based on whether or not a predetermined signal (a signal that triggers dispensing of the liquid agent) output from the batch mixer control device 3 has turned OFF. If it is determined that dispensing has finished (step 63=YES), the controller 21 proceeds to step 64. On the other hand, if it is determined that dispensing has not finished (step 63=NO), the controller 21 proceeds to step 62. That is, the controller 21 repeats the circulation type dispensing in progress process until dispensing has finished (until the signal turns OFF).

[0150] In step 64 (circulation type supply amount calculation process, supply amount calculation step), the controller 21 (supply amount calculation unit 31) performs a process of calculating the supply amount of the liquid agent supplied per batch. Specifically, the controller 21 (supply amount calculation unit 31) calculates the supply amount of the liquid agent input per batch based on the integrated value of the instantaneous flow rate during the cutting-out time T2 of the liquid agent, the integrated number of times during the cutting-out time T2, and the cutting-out time T2.

[0151] An example will be described with reference to FIG. 10. As an example, a case where the set amount per batch is 150 g (150 g / batch: 8.3 seconds) will be described. As shown in FIG. 10, when the feed time T2 is 8.3 seconds and the read frequency is once / 0.5 seconds, the controller 21 reads the instantaneous flow rate 16 times in total. When the sum (integrated value) of the measured values ​​is 17360, the controller 21 calculates the sum (17360) of the measured values ​​÷ the number of reads (16 times) = average measured value / min (1085 g / min) and calculates the average measured value / s (18.08 g) × solenoid valve open time (8.3 seconds) = amount of liquid agent dispensed per batch (150.06 ≒ 150 g / batch).

[0152] Here, as described above, conventionally, the cutting time manually input by the user to the auto feeder at the actual site was often set to a rough number such as "5 seconds" or "8 seconds". Furthermore, there were circumstances such as the batch mixer 2 timer relay being of analog type, making it difficult to display a reliable and accurate cutting time. For these reasons, conventionally, it was difficult to grasp the accurate cutting time T2 (for example, in units of 0.1 seconds), and there were cases where an error of about 1.0 seconds occurred between the cutting time T2 manually input to the auto feeder and the actual cutting time (cutting time T1). As a result, there was a problem such as an error occurring in the amount of liquid agent calculated as the supply amount per batch.

[0153] For example, as shown in FIG. 10, if the cut-out time T1 (the time during which the solenoid valve 10 opens and the liquid is actually supplied) is 8.3 seconds, but the supply amount per batch is calculated as 8.0 seconds, the calculated supply amount of liquid per batch will be 144.64 g even though the actual supply amount is 150.06 g (almost no error from the target amount), resulting in an error.

[0154] To cope with such a problem, the controller 21 can reduce the error between the actual supply amount of the liquid drug and the calculated supply amount of the liquid drug by improving the accuracy of the cutting out time T2. As a result, the controller 21 can increase the accuracy of error determination.

[0155] In step 65 (error calculation process), the controller 21 (error determination unit 32) performs a process of calculating an error. Specifically, the controller 21 (error determination unit 32) calculates, as an error, a deviation value between a target amount of the liquid per batch and the supply amount of the liquid calculated in the circulating supply amount calculation process in step 64. When the process of step 65 ends, the controller 21 shifts the process to step 66.

[0156] In step 66 (error determination process, error determination step), the controller 21 (error determination unit 32) performs a process of determining whether or not the value of the error calculated in the process of step 65 exceeds a threshold value. If it is determined that the error exceeds the threshold value (error>threshold value) (step 66=YES), the controller 21 moves the process to step 67. On the other hand, if it is determined that the error is equal to or less than the threshold value (error≦threshold value) (step 66=NO), the controller 21 returns the process to step 60 and performs the circulating standby process again.

[0157] In step 67 (notification process, notification step), the controller 21 (notification processing unit 33) performs a process of notifying that there is an error. Specifically, the controller 21 performs a process of notifying that the amount of liquid agent input into the batch mixer 2 is insufficient or over the target amount. For example, the controller 21 (notification processing unit 33) transmits a predetermined command or the like for causing the notification device 26 to execute a notification at a predetermined timing (for example, after the end of automatic operation). This process activates the notification device 26 to execute a notification that the error exceeds the threshold (liquid agent error notification). When the process of step 67 ends, the controller 21 returns the process to step 60 and executes the circulation type standby process again.

[0158] In this embodiment, notification that the error in the amount of liquid exceeds a threshold (liquid error notification) is performed by outputting an alarm sound (alert) from notification device 26 and displaying the liquid to be notified on display device 25. Specifically, when there is an excess or deficiency in the amount of resin, an alert is output by alert notification device 26 (alert by sound) and a display is performed by display device 25. Also, in this embodiment, the liquid error notification is performed at a timing after the automatic operation (one process) is completed. Note that various notifications (liquid error notification, etc.) may be performed by turning on a specified lamp, or may be performed by combining the output of an alarm sound and the lighting of a lamp.

[0159] The controller 21 of the present invention is not limited to this embodiment, and the liquid error notification may be only an alert output. According to this configuration, the on-site worker can easily notice the liquid error and can quickly respond to the liquid error. In addition, the timing of the liquid error notification is not limited to the end of automatic operation, and may be executed at the timing when the error determination process and the notification process are completed.

[0160] (14. Control during normal operation mode in case of non-circulating type) Next, control during normal operation executed by the controller 21 when the supply device 12 is of the non-circulation type will be described with reference to Figures 11 to 13. Figure 11 is a timing chart showing, in chronological order, control during normal operation executed by the controller 21 when the supply device 12 is of the non-circulation type.

[0161] As shown in FIG. 11, when the normal operation mode is turned ON, if the liquid agent to be transported by the non-circulating supply device 12B is a hardener, the controller 21 executes calculation of the mixing ratio of the hardener according to the sand temperature as a non-circulating standby process.

[0162] 11, when the liquid to be transported by the non-circulating supply device 12B starts to be dispensed (when a signal that triggers the start of supply of the liquid is received), the controller 21 performs non-circulating dispense processing, such as measuring pulse signals, accumulating the number of received pulses, and controlling the flow rate. Also, when the liquid is a hardener, the controller 21 calculates the compounding ratio of the hardener according to the sand temperature in addition to measuring and accumulating the pulses.

[0163] 11, the controller 21 performs a delay timer initiation process after the end of the feed time T2 of the liquid agent to be transported by the non-circulating supply device 12B. Specifically, as the delay timer initiation process, the controller 21 measures a pulse signal and accumulates the number of received pulses.

[0164] 11, after the delay timer in-progress process is completed, the controller 21 performs a non-circulating supply amount calculation process, an error determination process, and a notification process. These processes will be described in detail later.

[0165] (15. Treatment during normal operation for non-circulating type) Next, a non-circulation type normal operation process executed by the controller 21 for the liquid agent to be transported by the non-circulation type supply device 12B will be described with reference to Fig. 12. Fig. 12 is a flow chart showing the non-circulation type normal operation process.

[0166] In step 70 (standby processing for non-circulation type), if the liquid agent to be controlled is a hardener, the controller 21 (hardener blend ratio calculation unit 38) performs processing to calculate the blend ratio of the slow hardener and the fast hardener according to the temperature acquired from the temperature sensor 5. That is, even while waiting for the start of hardener feeding (standby), the controller 21 always calculates the blend ratio of the hardener according to the sand temperature to prepare for the start of hardener feeding.

[0167] In step 71, the controller 21 (signal receiving processing unit 39) performs processing to determine whether or not dispensing has started. As described above, the determination of whether or not dispensing has started is made based on whether or not a predetermined signal (a signal that triggers dispensing of the liquid agent) output from the batch mixer control device 3 has been received (whether or not the signal has turned ON). If it is determined that dispensing has started (step 71=YES), the controller 21 proceeds to processing in step 72. On the other hand, if it is determined that dispensing has not started (step 71=NO), the controller 21 proceeds to processing in step 70. That is, the controller 21 repeats the non-circulation standby processing until dispensing has started.

[0168] In step 72 (non-circulation type in-feed processing, flow rate measurement step), the controller 21 (flow rate measurement unit 30) performs a process of measuring pulses (a process of counting the number of pulses) and controls the flow rate of the liquid. Specifically, the controller 21 (flow rate measurement unit 30) measures the pulse signal output from the flowmeter 9 and stores the number of received pulses.

[0169] When the liquid agent to be controlled is a hardener, the controller 21 (hardener blending ratio calculation unit 38) calculates the blending ratio of the slow-hardening agent and the fast-hardening agent according to the temperature (sand temperature) acquired from the temperature sensor 5. In addition, the controller 21 (pump operation frequency setting unit 37) controls the flow rate and blending ratio of the hardener by controlling the operation frequency of the pump 8 so as to achieve that blending ratio.

[0170] Here, the measurement of the number of pulses will be described in more detail. As described above, in this embodiment, in the case of the non-circulating type, a pulse type flowmeter 9 is used. Furthermore, the controller 21 converts the flow rate when the pump 8 is operating into a pulse signal, and counts (integrates) the number of times the pulse is received. Furthermore, in the supply amount calculation process for the non-circulating type described later, the controller 21 calculates the supply amount per batch using the flow rate per pulse and the number of times the pulse is received. Note that in this embodiment, the pulse measurement looks at both the rising and falling edges. Therefore, it is more accurate than looking at only the rising edge.

[0171] In step 73, the controller 21 performs a process to determine whether or not dispensing has been completed. The determination of whether or not dispensing has been completed is made based on whether or not a predetermined signal (a signal that triggers dispensing of the liquid agent) output from the batch mixer control device 3 has turned OFF. If it is determined that dispensing has been completed (step 73=YES), the controller 21 proceeds to process step 74. On the other hand, if it is determined that dispensing has not been completed (step 73=NO), the controller 21 proceeds to process step 72. That is, the controller 21 repeats the non-circulation type dispensing in progress process until dispensing is completed (until the signal turns OFF).

[0172] In step 74 (delay timer activation process), the controller 21 (delay timer activation unit 34) performs a process of activating the delay timer. Specifically, the controller 21 performs a process of setting a predetermined time as the delay timer in a predetermined timer counter (delay timer counter). The delay timer time can be, for example, about 1 to 5 seconds. The delay timer time can be appropriately determined depending on the performance of the pump, etc. When the process of step 74 ends, the controller 21 moves the process to step 75.

[0173] In step 75 (delay timer in-progress processing, flow measurement step), the controller 21 (flow measurement unit 30) performs processing to measure pulses and to count the number of measured pulses. Specifically, the controller 21 measures the pulses output from the flowmeter 9, and counts and stores the measured pulses. In this way, the controller 21 continues to count pulses and accumulate the number of pulse receptions over the delay timer time, even after the cut-out time has ended.

[0174] In step 76, the controller 21 performs a process of determining whether or not the delay timer has expired. The determination of whether or not the delay timer has expired is performed based on whether or not the value of a predetermined timer counter (delay timer counter) has become "0." If it is determined that the delay timer has expired (step 76=YES), the controller 21 proceeds to the process of step 77. On the other hand, if it is determined that the delay timer has not expired (step 76=NO), the controller 21 proceeds to the process of step 75.

[0175] In step 77 (non-circulation supply amount calculation process, supply amount calculation step), the controller 21 (supply amount calculation unit 31) performs a process of calculating the amount of the liquid agent supplied per batch. Specifically, the controller 21 calculates the supply amount of the liquid agent input per batch based on the flow rate per pulse (e.g., 1 milliliter) and the number of pulses received during the cut-out time T2 and during the delay timer time ("cut-out time T2 + delay timer time = specific time"). That is, the controller 21 (supply amount calculation unit 31) calculates the supply amount by multiplying the total value of the number of pulses during the cut-out time T2 and the number of pulses for a predetermined time (delay timer time) from the end of the cut-out time T2 by the weight of the liquid agent per milliliter.

[0176] The specific gravity of the liquid varies depending on the type. The set amount per pulse also varies depending on the flowmeter 9 used. To accommodate this, the controller 21 is capable of inputting (accepting) the set amount of the liquid corresponding to each liquid and the flowmeter 9. The controller 21 also calculates the supply amount by multiplying the weight. Specifically, the controller 21 calculates the supply amount per batch as "number of pulses during a specific time x weight of liquid per pulse (e.g., weight of liquid per milliliter) = supply amount (g) per batch". The weight of liquid per pulse is appropriately selected depending on the performance of the flowmeter 9. For example, when the flowmeter 9 outputs a pulse signal every milliliter (1 milliliter / 1 pulse), the "weight of liquid per pulse" is the "weight of liquid per milliliter". Also, for example, if the flowmeter 9 outputs a pulse signal every 2 milliliters (2 milliliters / 1 pulse), the "weight of the liquid per pulse" is the "weight of the liquid per 2 milliliters."

[0177] Here, with reference to FIG. 13, the calculation of the supply amount in the case of the non-circulation type will be described. In the case of the non-circulation type, if the number of pulses is measured only during the extrusion time T2, an error occurs. Specifically, unlike the circulation type in which the pump 8 is always operated to transport the liquid, in the non-circulation type supply device 12B, the pump 8 starts operating when the liquid starts to be extruded. Therefore, after the pump 8 stops, dripping occurs due to the internal pressure of the pump 8, etc. In addition, if the flow rate (e.g., the number of pulses) is measured only during the operation time of the pump 8 (during the extrusion time T2), the amount of liquid due to dripping becomes an error. Furthermore, in the case of the non-circulation type, if the solenoid valve 10 is not provided, the error caused by dripping becomes significant.

[0178] To deal with this, the controller 21 can add the amount of liquid dripping after the pump 8 stops to the "amount of liquid supplied per batch" by starting a delay timer after the feed time T2 ends (see FIG. 13). As a result, the controller 21 can calculate the amount of liquid supplied as accurately as possible.

[0179] In step 78 (error calculation process), the controller 21 (error determination unit 32) performs a process of calculating an error. Specifically, the controller 21 (error determination unit 32) calculates, as an error, a deviation value between the target amount of the liquid agent per batch and the supply amount calculated in the non-circulating supply amount calculation process in step 77. When the process of step 78 ends, the controller 21 shifts the process to step 79.

[0180] In step 79 (error determination process, error determination step), the controller 21 (error determination unit 32) performs a process to determine whether or not the value of the error calculated in the process of step 78 exceeds a threshold value. If it is determined that the error exceeds the threshold value (error>threshold value) (step 79=YES), the controller 21 moves the process to step 80. On the other hand, if it is determined that the error is equal to or less than the threshold value (error≦threshold value) (step 79=NO), the controller 21 returns the process to step 70 and performs the non-circulating standby process again.

[0181] In step 80 (notification process, notification step), the controller 21 (notification processing unit 33) performs a process of notifying that there is an error. Specifically, the controller 21 performs a process of notifying that the amount of liquid agent charged into the batch mixer 2 is insufficient or over the set value. For example, the controller 21 (notification processing unit 33) transmits a predetermined command or the like for causing the notification device 26 to execute a notification at a predetermined timing. This process activates the notification device 26 to execute a notification that the error exceeds the threshold value (liquid agent error notification). When the process of step 80 ends, the controller 21 returns the process to step 70 and executes the non-circulation type standby process again.

[0182] In addition, when at least one type of liquid among the multiple liquids is transported by non-circulating supply device 12B, the liquid error notification is performed after both the automatic operation (one process) and the delay timer have finished.

[0183] In both the circulating and non-circulating types, in addition to the above-mentioned processing, the autofeeder 20 causes the display device 25 to display the flow rate (instantaneous flow rate) during circulation and normal operation.

[0184] (16. Control during calibration mode) Next, the control during the calibration mode executed by the controller 21 will be described with reference to FIGS.

[0185] The controller 21 is capable of executing control for automatically calculating the operation frequency of the pump 8. Here, the controller 21 uses a "pump constant" which is a value indicating the discharge capacity of the pump 8 for the automatic calculation of the operation frequency of the pump 8. However, an accurate cut-out time (=calibration time) is required to calculate an accurate pump constant.

[0186] The "pump constant" is an index indicating the performance of the pump 8. Specifically, the "pump constant" means the discharge amount per 1 Hz within a certain determined time. In other words, the relationship between the discharge amount, the pump constant, and the operating frequency is "discharge amount (g) = pump constant × operating frequency (Hz)".

[0187] The controller 21 calculates the pump constant based on the discharge rate for each arbitrary frequency (for example, for each 10 Hz) for operation frequencies between the lowest operation frequency (0 Hz) and the highest operation frequency (100 Hz). For example, for operation frequencies between 20 Hz and 30 Hz, the controller 21 calculates the pump constant at 20 Hz based on the discharge rate when the pump 8 is operated at 20 Hz, and calculates the pump constant at 30 Hz based on the discharge rate when the pump 8 is operated at 30 Hz. The controller 21 also calculates the pump constant within the range of 20 Hz to 30 Hz based on the pump constant at 20 Hz and the pump constant at 30 Hz.

[0188] For example, if the discharge volume at 20 Hz is "304 g" and the discharge volume at 30 Hz is "474 g," the pump constant in the range from 20 Hz to 30 Hz is "474 g - 304 g = 170 g ÷ 10 Hz (30 Hz - 20 Hz) = pump constant: 17.0 g / Hz (average discharge volume per Hz between 20 Hz and 30 Hz: 17.0 g).

[0189] Also, for example, if the discharge volume at 30 Hz is "474 g" and the discharge volume at 40 Hz is "652 g," the pump constant in the range from 30 Hz to 40 Hz is "652 g - 474 g = 178 g ÷ 10 Hz (40 Hz - 30 Hz) = pump constant: 17.8 g / Hz" (average discharge volume per Hz between 30 Hz and 40 Hz: 17.8 g).

[0190] Also, for example, if the discharge volume at 40 Hz is "652 g" and the discharge volume at 50 Hz is "835 g," the pump constant in the range from 40 Hz to 50 Hz is "835 g - 652 g = 183 g ÷ 10 Hz (50 Hz - 40 Hz) = pump constant: 18.3 g / Hz (average discharge volume per Hz between 40 Hz and 50 Hz: 18.3 g).

[0191] In this way, the discharge capacity (pump constant) of the pump 8 for the actual operating frequency is not a completely fixed value (constant) but a slightly changing value (parameter). Therefore, if the pump constant is calculated as a fixed value (constant), the error between the amount of liquid actually supplied and the assumed amount of liquid (set amount) may become large. To prevent such a situation, the autofeeder 20 (controller 21) calculates the pump constant between each operating frequency (for example, in a range of 10 Hz), and determines the operating frequency at which the pump 8 is operated based on the pump constant. This makes it possible to minimize the error in the amount of liquid actually discharged from the target value of the liquid.

[0192] Here, even if the pump is operated at the same frequency, the discharge amount changes due to factors such as pump deterioration, which causes an error in the amount of extrusion. Furthermore, an error in the amount of extrusion of the liquid may cause mold defects or casting defects. To address this problem, the autofeeder 20 discharges the liquid at each operating frequency in the calibration mode, and the user measures and inputs the amount of the discharged liquid, so that the controller 21 can automatically recalculate and reset the pump constant (resetting the pump constant).

[0193] The control in the pump constant resetting calibration mode executed by the controller 21 will be described with reference to Fig. 14. Fig. 14 is a timing chart showing the control executed by the controller 21 during normal operation in a chronological order.

[0194] The autofeeder 20 is provided with a number of calibration modes, including a "calibration mode for resetting pump constants." The "calibration mode for resetting pump constants" is an operation mode for resetting an accurate pump constant. In the autofeeder 20, the pump 8 is operated at a number of operating frequencies for a predetermined time (discharge time), and the user measures and inputs the amount of the discharged liquid, making it possible to reset an accurate pump constant.

[0195] Next, the control performed by the controller 21 when resetting the pump constant will be specifically described with reference to Figs. 14 to 16. The calibration mode for pump constant resetting is started when the user performs an operation such as touching a pump constant calibration button 120c on a calibration mode start screen 120 shown as an example in Fig. 18(a) and then touching a displayed operation start button (not shown).

[0196] In this embodiment, the controller 21 operates the pump 8 (e.g., a resin pump) at a plurality of operating frequencies (first to Nth operating frequencies) for resetting the pump constant for one type of liquid (e.g., a resin). As shown in FIG. 14 and FIG. 18(b), in this embodiment, the pump 8 can be operated at five operating frequencies: a first operating frequency (10 Hz), a second operating frequency (20 Hz), a third operating frequency (40 Hz), a fourth operating frequency (60 Hz), and a fifth operating frequency (80 Hz). In addition, the feed time T2 of each liquid stored in advance in the controller 21 is used as the feed time.

[0197] Here, the cut-out time T2 (the cut-out time read based on the signal output of the batch mixer 2) registered (stored) in the auto feeder 20 is automatically linked to the calibration operation time. This allows the controller 21 to prevent input errors in the cut-out time T2. Also, the controller 21 is capable of reading the signal reception time (cut-out time T1) from the batch mixer 2 in units of "0.1 seconds." This allows the controller 21 to improve the accuracy of the cut-out time T2 and thereby improve the calculation accuracy of the pump constant.

[0198] In the calibration mode, the controller 21 can reread various signals from the batch mixer control device 3. In other words, the controller 21 can reread the cut-out time. The cut-out time can be reread, for example, by displaying a calibration mode start screen 120 shown as an example in FIG. 18(a) on the display device 25 and the user touching a measurement start button 120b provided on the screen. As shown in FIG. 18(a), the cut-out time display area 120a provided on the calibration mode start screen 120 displays the currently stored (set) cut-out time T2.

[0199] Here, during the pump constant resetting calibration mode, the operation of the solenoid valve 10 and the pump 8 is controlled by the controller 21 regardless of whether the supply device 12 is of the circulating type or the non-circulating type. That is, during the normal operation mode when the supply device 12 is of the circulating type, the batch mixer control device 3 controls the opening and closing of the solenoid valve 10 as described above, but during the pump constant resetting calibration mode, the controller 21 controls the opening and closing of the solenoid valve 10.

[0200] 14, when the calibration mode for resetting pump constants is selected and the user performs an operation such as touching a calibration operation start button (not shown) provided on the screen of the display device 25, the controller 21 operates the pump 8 and the solenoid valve 10 to control the supply of the liquid for calibration (calibration operation). During the calibration operation, the pump 8 is operated at the selected operation frequency. The controller 21 also executes calibration operations (a total of five calibration operations from the first to fifth calibration operations) corresponding to each of the first to fifth operation frequencies, such as the first calibration operation corresponding to the first frequency (10 Hz).

[0201] In the example shown in this embodiment, calibration is performed five times in total in the range of operating frequencies from 10 Hz to 80 Hz (calibration number = 5 times), but the number of calibration operations is not limited to this embodiment. For example, if it is desired to further improve the calculation accuracy of the pump constant, the number of calibration operations may be increased, such as by performing a calibration operation every 10 Hz. The number of calibration operations may be set to 5 or more, or may be set to less than 5.

[0202] As shown in FIG. 18(b), a discharge amount input reception screen 121 is displayed on the display device 25. A discharge amount input area 121b is provided on the discharge amount input reception screen 121. In the auto-feeder 20, the user inputs the amount of liquid agent discharged in the calibration operation in the discharge amount input area 121b, and the discharge amount for that operation frequency is stored in the controller 21. The "discharge amount input reception" is performed for each operation frequency (first operation frequency to fifth operation frequency). The currently stored (set) cut-out time T2 is displayed in a cut-out time display area 121a provided on the discharge amount input reception screen 121.

[0203] 14, when the input of the discharge rate is completed, the controller 21 performs a process of calculating and resetting the pump constant related to the input operation frequency. For example, when the operation at the first frequency is terminated and the discharge rate when operating at the first frequency is input, the controller 21 calculates the pump constant and stores the calculated value as a new pump constant when operating at the first frequency (updates the pump constant).

[0204] (17. Processing in calibration mode for resetting pump constants) Next, the pump constant resetting calibration mode process executed by the controller 21 will be described with reference to Fig. 15. Fig. 15 is a flow chart showing the pump constant resetting calibration mode process. The process shown in Fig. 15 can be executed for each of the liquid materials, namely, the resin, the slow-hardening agent, and the fast-hardening agent.

[0205] In step 90, the controller 21 performs a first calibration operation process. In the first calibration operation process, the controller 21 reads the cut-out time T2, detects the pump constant at the first frequency, and resets the pump constant at the first frequency. The first calibration operation process will be described later with reference to FIG. 16. When the process of step 90 is completed, the controller 21 moves the process to step 91.

[0206] In step 91, the controller 21 performs a second calibration operation process. The second calibration operation process is similar to the first calibration operation process. Specifically, in the second calibration operation process, the pump 8 is operated at the second operation frequency, and the pump constant at the second operation frequency is calculated and reset. In addition, the third calibration operation process, the fourth calibration operation process, and the fifth calibration operation process in step 92 are also similar to the first calibration operation process, and in each calibration operation process, the pump 8 is operated at the corresponding frequency, and the pump constant for the corresponding operation frequency is calculated and reset.

[0207] For example, in the third calibration in-operation process, the pump 8 is operated at the third operating frequency, and the pump constant at the third operating frequency is calculated and reset. In the fourth calibration in-operation process, the pump 8 is operated at the fourth operating frequency, and the pump constant at the fourth frequency is calculated and reset. In the fifth calibration in-operation process, the pump 8 is operated at the fifth operating frequency, and the pump constant at the fifth operating frequency is calculated and reset.

[0208] When each of the calibration operation processes, i.e., the first calibration operation process (step 90), the second calibration operation process (step 91), the third calibration operation process (step 92), the fourth calibration operation process (step 93), and the fifth calibration operation process (step 94), is completed, the controller 21 ends the current calibration mode process for pump constant resetting. Note that, in the controller 21 of this embodiment, when another mode is selected before the calibration mode for pump constant resetting is completed (during the calibration mode for pump constant resetting), the controller 21 resets the pump constants for frequencies for which calibration has already been completed, and does not reset the pump constants for frequencies for which calibration has not been completed, and ends midway (the calibration mode for pump constant resetting is forcibly terminated midway).

[0209] Next, the first calibration in-operation process will be described with reference to Fig. 16. Fig. 16 is a flowchart showing the first calibration in-operation process.

[0210] In step 90-1, the controller 21 performs a process of reading in the cutting time. Specifically, the controller 21 selects and sets the cutting time T2 of the liquid agent to be calibrated this time from the cutting times T2 of each liquid agent stored in advance. That is, the controller 21 automatically sets the cutting time T2 stored in advance as the calibration operation time. When the process of step 90-1 is completed, the controller 21 moves the process to step 90-2.

[0211] In step 90-2, the controller 21 performs a process of determining whether or not the start of the first calibration operation (calibration operation at the first operating frequency) has been accepted. As described above, the start of the calibration operation is started by the user performing an operation such as touching a calibration start button (not shown) displayed on the display device 25. That is, the controller 21 accepts the start of operation by the user. If it is determined that the acceptance of the start of the first calibration operation has been completed (step 90-2=YES), the controller 21 moves the process to step 90-3. On the other hand, if it is determined that the acceptance of the start of the first calibration operation has not been completed (step 90-2=NO), the controller 21 waits until the acceptance of the start of operation is completed.

[0212] In step 90-3, the controller 21 operates the pump 8 at the first operating frequency (10 Hz). As described above, the controller 21 controls the operation of the solenoid valve 10 in addition to the operation of the pump 8. When the process of step 90-3 ends, the controller 21 shifts the process to step 90-4.

[0213] In step 90-4, the controller 21 performs a process of determining whether or not the cut-out time T2 has elapsed. If it is determined that the cut-out time T2 has elapsed (step 90-4=YES), the controller 21 proceeds to step 90-5. On the other hand, if it is determined that the cut-out time T2 has not elapsed (step 90-4=NO), the controller 21 proceeds to step 90-3. That is, the controller 21 continues to operate the pump 8 at the first operating frequency until the cut-out time T2 ends.

[0214] In step 90-5, the controller 21 performs a process of determining whether or not the discharge amount has been input. Specifically, the controller 21 determines whether or not the user has completed inputting the amount of liquid agent discharged at the target operating frequency into the display device 25. If it is determined that the discharge amount has been input (step 90-5=YES), the controller 21 moves the process to step 90-6. On the other hand, if it is determined that the cut-out time has not elapsed (step 90-5=NO), the controller 21 waits until input of the discharge amount is completed.

[0215] In step 90-6, the controller 21 stores the discharge amount of the first operating frequency. Specifically, the controller 21 stores the value input by the user for the amount of the liquid agent discharged at the target operating frequency. When the process of step 90-6 is completed, the controller 21 shifts the process to step 90-7.

[0216] In step 90-7, the controller 21 executes a pump constant calculation process. Specifically, the controller 21 calculates a new pump constant based on the discharge amount for each operation frequency. When the process of step 98 is completed, the controller 21 shifts the process to step 90-8.

[0217] In step 90-8, the controller 21 executes a pump constant resetting process (pump constant setting process). Specifically, the controller 21 stores (updates) the pump constant calculated in step 90-7 as a new pump constant. When the process of step 90-8 ends, the controller 21 ends the current first calibration operation process and shifts the process to a second calibration operation process.

[0218] (18. Cut-out time setting process) Next, the cut-out time setting process executed by the controller 21 will be described with reference to Fig. 17. Fig. 17 is a flowchart showing the cut-out time setting process executed by the controller 21. The cut-out time setting process shown in Fig. 17 can be executed for each of the resin and the hardener. As described above, the controller 21 can execute the cut-out time setting process during the initial setting of the auto feeder 20 or during the calibration mode.

[0219] In step 100, the controller 21 performs a process of determining whether or not it has started receiving a signal from the batch mixer 2. The determination of whether or not it has started receiving a signal is performed based on whether or not it has received a pump operation signal or an electromagnetic valve open signal for the liquid agent for which the cutting-out time T2 is to be set. For example, in the case of a circulating type, it is determined whether or not it has received an electromagnetic valve open signal, and in the case of a non-circulating type, it is determined whether or not it has received a pump operation signal. For example, when the liquid agent for which the cutting-out time T2 is to be set is a resin, it is performed based on whether or not it has started receiving a resin pump operation signal or a resin electromagnetic valve open signal. When the liquid agent for which the cutting-out time T2 is to be set is a hardener, it is performed based on whether or not it has started receiving a hardener pump operation signal or a hardener electromagnetic valve open signal. When the start of signal reception is detected (step 100=YES), the controller 21 moves the process to step 101. On the other hand, when the start of signal reception is not detected (step 100=NO), the controller 21 waits until the start of signal reception.

[0220] In step 101, the controller 21 counts the signal reception time. The controller 21 includes a timer relay (not shown) and measures (counts) the signal reception time from the batch mixer 2. When the process of step 101 ends, the controller 21 shifts the process to step 102.

[0221] In step 102, the controller 21 performs a process of determining whether or not the reception of a signal from the batch mixer 2 has ended. The determination of the end of the signal reception is made based on whether or not the reception of a pump operation signal of the liquid agent for which the cut-out time T2 is set has ended. For example, if the liquid agent for which the cut-out time T2 is set is a resin, the determination is made based on whether or not the reception of a resin pump operation signal has ended. Also, if the liquid agent for which the cut-out time T2 is set is a hardener, the determination is made based on whether or not the reception of a hardener pump operation signal has ended. If it is determined that the reception of the signal has ended (step 102=YES), the controller 21 moves the process to step 103. On the other hand, if it is not determined that the reception of the signal has ended (step 102=NO), the controller 21 returns the process to step 101 and continues counting the signal reception time.

[0222] In step 103, the controller 21 performs a process of setting the excretion time T2. Specifically, the controller 21 stores the time measured (counted) by the process of step 101 as the excretion time T2 of the target liquid agent. When the process ends, the controller 21 ends the current excretion time setting process.

[0223] In this way, the controller 21 can automatically measure and store the cut-out time T2. Therefore, the controller 21 does not need to manually measure the cut-out time T1 of the batch mixer 2, and can significantly improve the accuracy of the cut-out time T2.

[0224] (19. Mold making process) Next, a mold making process (self-hardening mold making process) using the mold making apparatus 1 will be described. When the operation of the batch mixer 2 is started, sand is fed from the sand hopper 4 to the batch mixer 2. The auto feeder 20 (controller 21) also controls the feeders 12 corresponding to the respective liquid agents to feed the resin and hardener to the batch mixer 2. When the sand and liquid agents (resin and hardener) are fed to the batch mixer 2, the batch mixer 2 kneads the fed sand and liquid agents.

[0225] After the above steps are completed, the material (mixed sand) mixed in the batch mixer 2 is poured into a frame 6. After the mixed material has hardened, the frame 6 is removed and the master model (not shown) is removed, thereby forming a mold.

[0226] Next, a mold making process (gas-hardening mold making process) using the mold making apparatus 200 associated with the cold box will be described. As shown in Fig. 19, the mold making apparatus 200 includes a batch mixer 2, a sand hopper 4, an auto-feeder 20, two tanks 7, two pumps 8, two flow meters 9, and two solenoid valves 10. The mold making apparatus 200 also includes a sand magazine 201, a gas injector 202, and a mold 203. Each of the two tanks 7 stores resin.

[0227] When the operation of the batch mixer 2 is started, sand material is fed from the sand hopper 4 into the batch mixer 2. In addition, the auto feeder 20 (controller 21) controls the respective feeders 12 corresponding to the two types of liquid agents (resins) to feed them to the batch mixer 2. The mixed sand fed into the batch mixer 2 is blown into a mold 203 by the sand magazine 201 (blow molding). Furthermore, when a hardening catalyst gas (e.g., amine gas) is sprayed into the mold 203, the mixed sand in the mold 203 hardens.

[0228] (20. Actions and Effects) Next, the operation and effects of the controller 21 of this embodiment will be described.

[0229] (1) As described above, the controller 21 of this embodiment controls the supply of a plurality of types of liquids, including a resin and a hardener, to the batch mixer 2 using the respective supply devices 12 corresponding to these liquids. The controller 21 also includes a flow rate measuring unit 30 that measures the flow rate of the liquid, and a supply amount calculating unit 31 that calculates the amount of liquid supplied per batch using the flow rate during a predetermined time (during the cutting time T2 or during a specific time) measured by the flow rate measuring unit 30. The controller 21 also includes an error determining unit 32 that determines whether or not the error between a preset target amount of liquid per batch and the amount of liquid supplied per batch calculated by the supply amount calculating unit 31 exceeds a threshold value, and an alarm processing unit 33 that performs processing to cause the alarm device 26 to issue an alarm when the error determining unit 32 determines that the error exceeds the threshold value.

[0230] In the controller 21 of the present embodiment, in the molding of a mold using the batch mixer 2, the error between the supply amount per batch and the target amount of the liquid is automatically calculated, and when the error exceeds a threshold value, the alarm device 26 is made to execute an alarm. For example, when there is a possibility that an excess or shortage (error) of the liquid may lead to a defective mold, the controller 21 of the present embodiment makes the alarm device 26 execute an alarm such as an alarm sound (alert). In this way, the controller 21 of the present embodiment can promptly notify an operator of the possibility of a defective mold when there is an excess or shortage in the supply amount of the liquid per batch. As a result, the controller 21 of the present embodiment allows an operator to promptly grasp that the mold may be defective. For example, according to the controller 21 of the present embodiment, even an inexperienced operator or an inexperienced operator can promptly grasp the defect of the mold. Note that the control device of the present invention may be configured to notify an alert by email. For example, an alert such as an excess or shortage of the liquid or an abnormality in the flow rate may be notified to the email address of the administrator (such as a site manager) of the controller 21 (control device).

[0231] (2) As described above, in the controller 21 of this embodiment, when the supply device 12 is a circulating type, the flow rate measuring unit 30 measures the instantaneous flow rate and the cumulative number of instantaneous flow rates of the liquid during a predetermined time transported by the circulating supply device 12A. In addition, in the controller 21, the supply amount calculating unit 31 calculates the amount of the liquid transported by the circulating supply device 12A per batch using the instantaneous flow rate, the cumulative number, and the cut-out time T2 measured by the flow rate measuring unit 30.

[0232] With the above-mentioned configuration, the controller 21 can appropriately measure the flow rate of the circulating supply device 12, and can improve the accuracy of calculation of the amount of liquid actually supplied to the batch mixer 2. This allows the controller 21 to improve the accuracy of calculation of the error from the target amount of liquid. As a result, the controller 21 of this embodiment can accurately notify of excess or deficiency of liquid.

[0233] (3) As described above, in the controller 21 of this embodiment, when the supply device 12 is a non-circulating supply device, the flow rate measuring unit 30 measures the number of pulses output from the flowmeter 9 during a predetermined time for the liquid transported by the non-circulating supply device 12B. Also, in the controller 21, the supply amount calculating unit 31 is configured to calculate the amount of the liquid transported by the non-circulating supply device 12B per batch, using the number of pulses measured by the flow rate measuring unit 30.

[0234] With the above-mentioned configuration, the controller 21 can appropriately measure the flow rate of the non-circulating supply device 12, and can improve the accuracy of the amount of liquid actually supplied to the batch mixer 2. This allows the controller 21 to improve the accuracy of calculating the error from the target amount of liquid. As a result, the controller 21 of this embodiment can accurately notify of excess or deficiency of the liquid.

[0235] (4) As described above, the controller 21 of the present embodiment includes a pump 8 that transports the liquid agent in the supply device 12, a pump constant calculation unit 35 that calculates a pump constant that indicates the performance of the pump 8, and a pump constant setting unit 36 ​​that sets the pump constant. In the controller 21, the pump constant calculation unit 35 calculates the pump constant using the discharge amount of the liquid agent when the liquid agent is discharged for a predetermined time and the operating frequency of the pump, and the pump constant setting unit 36 ​​stores the pump constant calculated by the pump constant calculation unit 35 as a new pump constant.

[0236] With the above-described configuration, the controller 21 can flexibly respond to changes in pump performance due to factors such as deterioration of the pump 8. Specifically, the controller 21 of this embodiment can readjust the frequency of the pump 8 by updating the pump constant when the performance of the pump 8 changes. This allows the controller 21 of this embodiment to supply the liquid agent at an amount with an extremely small error relative to the target amount even when the pump performance changes. That is, the controller 21 of this embodiment can suitably maintain a supply amount with a small error and suppress defects in the mold.

[0237] (5) As described above, in the controller 21 of this embodiment, when the supply device 12 is of a non-circulating type, the flow rate measuring unit 30 measures the number of pulses output from the flowmeter 9 for the liquid transported by the non-circulating supply device 12B over a specific time period from the start of the feed time T2 to a specific timing after the feed time T2 ends. In addition, in the controller 21, the supply amount calculating unit 31 calculates the amount of the liquid transported by the non-circulating supply device 12B per batch using the number of pulses during the specific time period measured by the flow rate measuring unit 30.

[0238] With the above-mentioned configuration, the controller 21 can calculate the supply amount per batch, including the dripping amount of the liquid after the pump 8 has stopped. This allows the controller 21 of this embodiment to calculate the supply amount of the liquid with higher accuracy when a non-circulating supply device 12 is used. Furthermore, the controller 21 of this embodiment can improve the accuracy of error determination by improving the calculation accuracy of the supply amount of the liquid, and can improve the accuracy of reporting mold defects.

[0239] (6) The control method of this embodiment is a control method for controlling the supply of multiple types of liquid to the batch mixer 2 using each supply device 12 corresponding to these liquids, and includes a flow rate measurement step for measuring the flow rate of the liquid, a supply amount calculation step for calculating the amount of liquid supplied per batch using the flow rate during a predetermined time measured in the flow rate measurement step, an error determination step for determining whether or not an error between a preset target amount of liquid per batch and the amount of liquid supplied per batch calculated in the supply amount calculation step exceeds a threshold value, and an alarm processing step for causing an alarm device 26 to execute an alarm when it is determined in the error determination step that the error exceeds the threshold value.

[0240] In the control method of this embodiment, in the molding of a mold using the batch mixer 2, the error between the supply amount per batch and the target amount is automatically calculated, and when the error exceeds a threshold value, the notification device 26 is made to execute a notification. For example, in the control method of this embodiment, when there is a possibility that an excess or shortage (error) of the liquid may lead to a mold defect, the notification device 26 is made to execute a notification such as an alarm sound (alert). In this way, in the control method of this embodiment, when there is an excess or shortage of the liquid supply amount per batch, the operator can be promptly notified of the fact. As a result, the control method of this embodiment allows the operator to quickly grasp that the mold may be defective. For example, according to the control method of this embodiment, even an inexperienced operator or an inexperienced operator can quickly grasp the defect of the mold. In the control method of the present invention, the alert may be notified by email. For example, an alert such as an excess or shortage of the liquid or an abnormality in the flow rate may be notified to the email address of the administrator (such as the on-site person in charge) of the controller 21 (control device).

[0241] The present invention is not limited to the above-described embodiment, and other embodiments may be made within the scope of the claims, based on the teachings and spirit of the present invention. The components of the above-described embodiment may be arbitrarily selected and combined. In addition, any component of the embodiment may be arbitrarily combined with any component described in the Summary of the Invention or any component that embodies any component described in the Summary of the Invention. [Industrial Applicability]

[0242] The present invention can be suitably employed as an apparatus for controlling the flow rate of a liquid during molding of a casting mold, and as a method for controlling the flow rate of a liquid. [Explanation of symbols]

[0243] 1. Mold molding equipment 2 Batch Mixer 8. Pump 9 Flow meter 10. Solenoid valve 12 Feeding device 12A circulation type feeding device 12B Non-circulating feeding device 20 Auto Feeder 21 Controller 25 Display device 26 Alarm device 30 Flow Meter 31 Supply amount calculation section 32 Error judgment section 33 Notification processing section 34 Delay timer activation section 35 Pump constant calculation section 36 Pump constant setting section T1, T2 Cut-out time

Claims

1. A control device that controls supply of a plurality of types of liquid agents, including a resin and a hardener, to a batch mixer using respective supply devices corresponding to the liquid agents, A flow rate measuring unit that measures a flow rate of the liquid agent; a supply amount calculation unit that calculates an amount of the liquid agent supplied per batch using the flow rate during a predetermined time period measured by the flow rate measurement unit; an error determination unit that determines whether or not an error between a preset target amount of the liquid per batch and the amount of the liquid supplied per batch calculated by the supply amount calculation unit exceeds a threshold value; a notification processing unit that performs processing for causing a notification device to issue a notification when the error determination unit determines that the error exceeds the threshold value; A control device comprising:

2. Among the supply devices, a circulation type supply device is one that has a flow path that returns the liquid to a tank and is capable of circulating the liquid, The flow rate measuring unit is Measure an instantaneous flow rate of the liquid agent conveyed by the circulating supply device during a predetermined time and an integrated number of times of the instantaneous flow rate; The supply amount calculation unit Calculating the amount of the liquid agent supplied per batch using the instantaneous flow rate and the cumulative number measured by the flow rate measuring unit for the liquid agent transported by the circulating supply device. The control device according to claim 1 .

3. Among the above-mentioned supply devices, a non-circulating supply device is one that does not have a flow path for returning the liquid to a tank and circulating the liquid. The flow rate measuring unit is Measure the number of pulses output from a flow meter during a predetermined time for the liquid agent transported by the non-circulating supply device; The supply amount calculation unit The amount of the liquid agent supplied per batch is calculated using the number of pulses measured by the flow rate measuring unit for the liquid agent transported by the non-circulating supply device.

3. The control device according to claim 1 or 2.

4. The supply device is provided with a pump that transports the liquid agent, A pump constant calculation unit that calculates a pump constant indicating the performance of the pump; A pump constant setting unit that sets the pump constant, The pump constant calculation unit calculating the pump constant using a discharge amount of the liquid when the liquid is discharged for a predetermined time and an operating frequency of the pump; The pump constant setting unit is The pump constant calculated by the pump constant calculation unit is stored as a new pump constant.

3. The control device according to claim 1 or 2.

5. Among the supply devices, a non-circulating supply device is one that does not have a flow path for returning the liquid agent to a tank and circulating the liquid agent; If the time set as the supply time of the liquid agent to the batch mixer is the cut-out time, The flow rate measuring unit is Measure the number of pulses output from a flow meter for the liquid agent transported by the non-circulating supply device over a specific time period from the start of the feed time to a specific timing after the end of the feed time; The supply amount calculation unit For the liquid transported by the non-circulating supply device, the amount of the liquid supplied per batch is calculated using the number of pulses during the specific time period measured by the flow rate measurement unit.

3. The control device according to claim 1 or 2.

6. A control method for controlling supply of a plurality of types of liquid agents, including a resin and a hardener, to a batch mixer using respective supply devices corresponding to the liquid agents, the method comprising: a flow rate measuring step of measuring a flow rate of the liquid; a supply amount calculation step of calculating an amount of the liquid agent supplied per batch using the flow rate during a predetermined time period measured in the flow rate measurement step; an error determination step of determining whether or not an error between a preset target amount of the liquid per batch and the amount of the liquid supplied per batch calculated in the supply amount calculation step exceeds a threshold value; and a notification processing step of causing a notification device to execute notification when it is determined in the error determination step that the error exceeds the threshold value. A control method comprising:

Images