Casting apparatus, and control method therefor

Abstract

To provide a casting apparatus capable of casting a high-quality cast, and to provide a control method therefor.SOLUTION: A casting apparatus according to the present disclosure comprises: a die for which a mold coating is formed on a molten metal casting face; a molten metal charging part for casting molten metal onto the molten metal casting face; a determination part for determining quality of a surface shape of a cast formed with the die; and a control part for adjusting a die-releasing speed of the die, based on a determination result obtained by the determination part. Thus, the casting apparatus according to the present disclosure can cast a high-quality cast.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a casting apparatus and a control method thereof. [Background technology]

[0002] Patent Document 1 discloses a mold casting method in which a mold wash is applied to a molten metal casting surface of a mold to form a mold wash, and molten metal is cast onto the molten metal casting surface covered with the mold wash. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2011-212714 A Summary of the Invention [Problem to be solved by the invention]

[0004] The method disclosed in Patent Document 1 had a problem in that if a part of the mold coat becomes damaged or worn due to repeated casting, the shape of the damaged or worn part of the mold coat is transferred to the blank, making it impossible to cast a high-quality casting.

[0005] The present disclosure has been made in consideration of the above background, and has an object to provide a casting apparatus capable of casting high-quality castings, and a control method thereof. [Means for solving the problem]

[0006] A casting apparatus according to the present disclosure includes a mold having a mold wash formed on its molten metal casting surface, a molten metal injection section for pouring molten metal onto the molten metal casting surface of the mold having the mold wash formed thereon, a judgment section for judging the quality of the surface shape of a casting formed by the mold, and a control section for adjusting a mold release speed of the mold based on the judgment result by the judgment section. When a sign of quality deterioration is observed in the surface shape of the casting due to an influence such as damage to the mold wash formed on the molten metal casting surface of the mold, this casting apparatus suppresses the deterioration of the quality of the surface shape of the casting by, for example, slowing down the mold release speed. This allows the casting apparatus to continue to cast high-quality castings.

[0007] The method for controlling a casting apparatus according to the present disclosure is a method for controlling a casting apparatus including a mold having a mold wash formed on its molten metal casting surface and a molten metal input section for casting molten metal onto the molten metal casting surface of the mold having the mold wash formed thereon, and includes judging the quality of the surface shape of a casting formed by the mold and adjusting the mold release speed for the next casting to be formed based on the judgment result. When there are signs of deterioration in the quality of the surface shape of the casting due to the influence of damage to the mold wash formed on the molten metal casting surface of the mold, the method for controlling a casting apparatus suppresses the deterioration in the quality of the surface shape of the casting by, for example, slowing down the mold release speed. This method for controlling a casting apparatus allows the casting of high quality castings to be continued. Effect of the Invention

[0008] The present disclosure makes it possible to provide a casting apparatus capable of casting high quality castings, and a control method thereof. [Brief description of the drawings]

[0009] [Figure 1] 1 is a block diagram showing an example of the configuration of a casting device according to the present disclosure. FIG. [Diagram 2] FIG. 1 is a diagram showing the relationship between the number of casting shots and the actual area of ​​peeled mold coat. [Diagram 3] A figure showing the relationship between the mold coat peeling area determined by the casting apparatus according to the present disclosure using a trained model and the actual mold coat peeling area. [Figure 4] FIG. 1 is a diagram showing photographed images of the surfaces of a number of castings with different numbers of casting shots. [Diagram 5] FIG. 13 is a graph showing the relationship between demolding speed and coating peeling area. [Figure 6] 4 is a flowchart illustrating the operation of the casting device according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention will be described below through embodiments of the invention, but the invention according to the claims is not limited to the following embodiments. In addition, not all of the configurations described in the embodiments are necessarily essential means for solving the problems. For clarity of explanation, the following description and drawings are omitted and simplified as appropriate. In each drawing, the same elements are given the same reference numerals, and repeated explanations are omitted as necessary.

[0011] Fig. 1 is a block diagram showing an example of the configuration of a casting apparatus 1 according to the present disclosure. When there are signs of deterioration in the quality of the surface shape of the casting due to the influence of defects in the mold coat formed on the molten metal casting surface of the mold, the casting apparatus 1 according to the present disclosure suppresses deterioration in the quality of the surface shape of the casting by slowing down the mold release speed. This allows the casting apparatus 1 according to the present disclosure to continue casting high quality castings. This will be specifically described below.

[0012] As shown in FIG. 1, the casting apparatus 1 includes at least a mold 11, a molten metal input section 12, a determination section 13, and a control section .

[0013] A mold wash 101 is formed on the molten metal casting surface of the mold 11. The mold wash 101 is formed by spraying (applying) a mold wash diluted with water onto the molten metal casting surface of the mold 11 using a spray gun or the like. The mold wash may be, for example, ALO3 or ZnO. The mold wash 101 makes it easier to remove the rough material of the casting 102 molded by the mold 11 from the mold 11 (i.e., improves the releasability of the mold 11) and improves the moisture retention of the mold 11.

[0014] The molten metal input section 12 pours (casts) molten metal, such as aluminum, onto the molten metal casting surface of the die 11 on which the mold wash 101 is formed. The molten metal input into the die 11 is cooled and solidified within the die 11, becoming a raw material for the casting 102 formed into a desired shape. The raw material for the casting 102 formed into a desired shape by the die 11 is removed from the die 11.

[0015] The determination unit 13 determines the quality of the surface shape of the casting 102 formed by the mold 11. For example, the determination unit 13 determines the quality of the surface shape of the casting 102 by analyzing an image of the surface of the casting 102 captured by an imaging device such as a camera.

[0016] Here, if the mold coat 101 formed on the molten metal casting surface of the mold 11 is damaged or worn, the shape of the damaged or worn part of the mold coat 101 is transferred to the raw material, and the surface shape of the part of the surface of the casting 102 corresponding to the damage or the like of the mold coat 101 may differ from the ideal surface shape. Therefore, the judgment unit 13 judges the casting 102 to be a good product if the area of ​​the difference between the surface shape of the casting 102 and the ideal surface shape is within the allowable range, and judges the casting 102 to be a defective product if the area of ​​the difference between the surface shape of the casting 102 and the ideal surface shape is outside the allowable range. Hereinafter, the area of ​​the part of the surface of the casting 102 that differs from the ideal surface shape due to the effect of damage or the like of the mold coat 101 is also referred to as the coat peeling area.

[0017] Furthermore, even if the coating peeling area of ​​the casting 102 is within the allowable range, when it is likely to exceed the allowable range, the determining unit 13 determines that the surface shape of the casting 102 shows signs of quality deterioration. Alternatively, the determining unit 13 may determine that the surface shape of the casting 102 shows signs of quality deterioration when the degree of increase in the coating peeling area of ​​the casting 102 with an increase in the number of casting shots is large compared to past statistical values. The number of casting shots refers to the number of times molten metal has been cast into the mold 11.

[0018] Fig. 2 is a diagram showing the relationship between the number of casting shots and the area of ​​peeled coat, in which the dotted line represents past statistical values ​​and the solid line represents a set threshold value.

[0019] As shown in Figure 2, the coating peeling area increases as the number of casting shots increases. Here, the allowable range of the coating peeling area is set to 10 mm 2 Then, the judgment section 13 is 2 Castings 102 within the above range are judged as good products, and the coating peeling area is 10 mm 2 In addition, even if the coating peeling area is within the allowable range, if it is likely to exceed the allowable range, the determining unit 13 determines that the coating peeling area is greater than 8 mm, for example, as a defective product. 2 , it is determined that there is a sign of quality deterioration in the surface shape of the casting 102. Furthermore, the determining unit 13 may determine that there is a sign of quality deterioration in the surface shape of the casting 102 when the degree of increase in the coat peeling area of ​​the casting 102 accompanying an increase in the number of casting shots is large compared to past statistical values, for example, when it exceeds a set threshold value (solid line).

[0020] Furthermore, the determination unit 13 may be configured to determine the quality of the surface shape of the casting 102 by using a trained model generated by machine learning using photographed images of the surfaces of a plurality of castings. In machine learning, for example, learning is performed using photographed images of a plurality of castings having ideal surface shapes. This makes it possible to distinguish between the ideal surface shape of a casting and a surface shape of a casting that differs from the ideal surface shape. By using this trained model, the determination unit 13 can more accurately determine the quality of the surface shape of the casting 102.

[0021] Fig. 3 is a diagram showing the relationship between the mold coat peeling area identified by the judgment unit 13 using the trained model and the actual mold coat peeling area. In Fig. 3, the mold coat peeling area identified by the judgment unit 13 using the trained model is expressed in terms of the number of pixels. Fig. 4 is a diagram showing photographed images of the surfaces of a plurality of castings 102 with different numbers of casting shots. The upper diagram of Fig. 4 shows a photographed image of the casting 102 in the second shot, the middle diagram of Fig. 4 shows a photographed image of the casting 102 in the 55th shot, and the lower diagram of Fig. 4 shows a photographed image of the casting 102 in the 103rd shot.

[0022] 3 and 4, there is a correlation between the area of ​​peeled coat determined by the determination unit 13 using the trained model and the actual area of ​​peeled coat. In other words, the determination unit 13 can determine the area of ​​peeled coat of the casting 102 with high accuracy by using the trained model.

[0023] The control unit 14 adjusts at least the demolding speed of the mold 11 based on the judgment result by the judgment unit 13. Specifically, the control unit 14 slows down the demolding speed of the mold 11 when the judgment unit 13 judges that the surface shape of the casting 102 shows signs of quality deterioration. Alternatively, the control unit 14 may slow down the demolding speed of the mold 11 as the area of ​​the difference between the surface shape of the casting and the ideal surface shape increases. The slower the demolding speed of the mold 11, the more the coating peeling of the casting 102 is suppressed.

[0024] Fig. 5 is a diagram showing the relationship between the demolding speed and the area of ​​peeled mold coat. As shown in Fig. 5, the slower the demolding speed, the smaller the area of ​​peeled mold coat of the casting 102. Therefore, when a sign of quality deterioration is observed in the surface shape of the casting 102, the casting apparatus 1 can suppress quality deterioration of the casting 102 by slowing down the demolding speed of the mold 11 to suppress peeling of the mold coat of the casting 102. However, when no sign of quality deterioration is observed in the surface shape of the casting 102, the casting apparatus 1 can efficiently cast the casting 102 by increasing the demolding speed of the mold 11.

[0025] Furthermore, when the determining unit 13 determines that the casting 102 is defective or that the surface shape of the casting 102 shows a sign of quality deterioration, the control unit 14 may issue a notification to prompt the operator to repair the mold coat 101. The notification to prompt the operator to repair the mold coat 101 may be output as a voice through a speaker or displayed on a monitor. A worker who receives this notification can repair the mold coat 101. When the casting apparatus 1 has a function for automatically repairing the mold coat 101, the control unit 14 may be configured to instruct the function to repair it.

[0026] Next, the operation of the casting apparatus 1 will be described with reference to Fig. 6. Fig. 6 is a flow chart showing the operation of the casting apparatus 1.

[0027] First, in the casting apparatus 1, conditions are set according to the casting product 102 to be cast (step S101). Then, a mold wash 101 is formed on the molten metal casting surface of the mold 11 (step S102).

[0028] Thereafter, the casting apparatus 1 pours molten metal such as aluminum onto the molten metal casting surface of the mold 11 on which the mold wash 101 is formed (step S103). The molten metal poured into the mold 11 is cooled and solidified within the mold 11, becoming a raw material for the casting 102 formed into a desired shape.

[0029] Thereafter, the casting device 1 removes the rough material of the casting 102 formed by the die 11 from the die 11 (step S104), and transports it (step S105).

[0030] Thereafter, the casting apparatus 1 judges the quality of the surface shape of the casting 102 formed by the die 11 using, for example, a trained model generated by machine learning using photographed images of the surfaces of a plurality of castings (step S106).

[0031] For example, if the area of ​​the difference between the surface shape of the casting 102 and the ideal surface shape is within an acceptable range, the casting device 1 judges the casting 102 to be a good product, and if the area of ​​the difference between the surface shape of the casting 102 and the ideal surface shape is outside the acceptable range, the casting device 1 judges the casting 102 to be a defective product.

[0032] Even if the coating peeling area of ​​the casting 102 is within the allowable range, if it is about to exceed the allowable range, the casting apparatus 1 determines that the surface shape of the casting 102 shows signs of quality deterioration. Furthermore, the casting apparatus 1 may determine that the surface shape of the casting 102 shows signs of quality deterioration if the degree of increase in the coating peeling area of ​​the casting 102 with an increase in the number of casting shots is large compared to past statistical values.

[0033] Thereafter, the casting apparatus 1 adjusts the release speed of the mold 11 as necessary based on the result of the determination (step S107). Specifically, when the casting apparatus 1 determines that the surface shape of the casting 102 shows signs of quality deterioration, it slows down the release speed of the mold 11 for the next casting 102 to be formed. The slower the release speed of the mold 11, the more the coating peeling of the casting 102 is suppressed.

[0034] Furthermore, the casting apparatus 1 issues an instruction to repair the mold coat 101 as necessary based on the judgment result (step S108). Specifically, if the casting apparatus 1 judges the casting 102 to be defective or judges that the surface shape of the casting 102 shows signs of quality deterioration, it issues a notice to prompt the operator to repair the mold coat 101. The notice to prompt the operator to repair the mold coat 101 is output as a voice message via a speaker or displayed on a monitor. A worker who receives this notice can repair the mold coat 101.

[0035] Thereafter, if the predetermined number of casting shots has not been performed, the casting apparatus 1 returns to the processing of step S103 (NO in step S109), and if the predetermined number of casting shots has been performed, ends the casting processing (YES in step S109).

[0036] In this manner, when there are signs of deterioration in the quality of the surface shape of the casting 102 due to, for example, damage to the mold wash 101 formed on the molten metal casting surface of the mold 11, the casting apparatus 1 according to the present disclosure suppresses deterioration in the quality of the surface shape of the casting 102 by slowing down the demolding speed of the mold 11. This allows the casting apparatus 1 according to the present disclosure to continue casting high-quality castings 102.

[0037] In addition, in the present disclosure, a part or all of the processing of the casting apparatus 1 can be realized by causing a CPU (Central Processing Unit) to execute a computer program.

[0038] The above-mentioned program includes a set of instructions (or software code) for making the computer perform one or more functions described in the embodiment when the program is loaded into the computer. The program may be stored in a non-transitory computer-readable medium or a tangible storage medium. By way of example and not limitation, the computer-readable medium or the tangible storage medium includes a random-access memory (RAM), a read-only memory (ROM), a flash memory, a solid-state drive (SSD) or other memory technology, a CD-ROM, a digital versatile disc (DVD), a Blu-ray® disk or other optical disk storage, a magnetic cassette, a magnetic tape, a magnetic disk storage or other magnetic storage device. The program may be transmitted on a transitory computer-readable medium or a communication medium. By way of example and not limitation, the transitory computer-readable medium or the communication medium includes an electrical, optical, acoustic, or other form of propagating signal.

[0039] A part or all of the above-described embodiments can be described as, but is not limited to, the following supplementary notes.

[0040] (Appendix 1) A mold having a mold coat formed on a molten metal casting surface; a molten metal input section for pouring molten metal onto a molten metal pouring surface of the mold on which the mold wash is formed; A control program for causing a computer to execute a control process for a casting device, comprising: A process for determining the quality of a surface shape of a casting formed by the mold; adjusting a demolding speed of the mold for a next casting based on the result of the determination; A control program that causes a computer to execute the above. [Explanation of symbols]

[0041] 1 Casting equipment 11 Mold 12 Molten metal inlet 13 Judgment section 14 Control section 101 Coating 102 Castings

Claims

1. A mold having a mold coat formed on a molten metal casting surface; a molten metal input section for pouring molten metal onto a molten metal pouring surface of the mold on which the mold wash is formed; a judgment unit for judging the quality of a surface shape of a casting formed by the die; A control unit that adjusts a demolding speed of the mold based on a result of the determination by the determination unit; A casting device comprising:

2. The control unit slows down a demolding speed of the mold when the determination unit determines that a sign of quality deterioration is observed in the surface shape of the casting. The casting apparatus of claim 1.

3. The determination unit determines the quality of the surface shape of the casting by using a trained model generated by machine learning using images of the surfaces of a plurality of castings. The casting apparatus of claim 1.

4. The control unit further instructs repair of the mold coat formed on the molten metal casting surface of the mold based on the judgment result by the judgment unit. The casting apparatus of claim 1.

5. A mold having a mold coat formed on a molten metal casting surface; a molten metal input section for pouring molten metal onto a molten metal pouring surface of the mold on which the mold wash is formed; A method for controlling a casting machine, comprising: Determining the quality of the surface shape of a casting formed by the mold; Based on the result of the determination, a demolding speed of the mold for a next casting is adjusted. A method for controlling a casting device.

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