Neutron setting method

Abstract

To provide a core setting method capable of dispensing with positioning by a clamp mechanism.SOLUTION: A core setting method according to the present embodiment is a core setting method for setting a plurality of cores 10-50 into a cavity 91 of a mold 90. The method for setting cores 10-50 includes: a core combination step of combining the plurality of cores 10-50 outside the cavity 91; a negative pressure adsorption step of adsorbing each of the combined cores 10-50 under negative pressure; and a positioning aggregation step of aggregating a plurality of core aggregates 12-52 for determining positions of the plurality of negatively pressure-adsorbed cores 10-50 into a plurality of mold aggregates 92a-92e corresponding to the plurality of core aggregates 12-52 in the mold 90.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a method for setting neutrons.

Background Art

[0002] Patent Document 1 describes that when setting neutrons, one end of the spacer portion of the neutron is adsorbed and held by an adsorption mechanism, and the other end of the neutron is held by a clamp mechanism. In the setting method of Patent Document 1, after engaging the other end of the neutron with the clamp mechanism, the adsorption grip is released, and the neutron is slid to be set in the cavity.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Depending on the shape / material of the neutron, the neutron may collapse when clamped. In order to prevent unintentional collapse of the neutron, a method of setting the neutron without relying on machinery can be considered, but in that case, the cycle time becomes long, which is disadvantageous from the viewpoint of productivity.

[0005] The present invention has been made to solve such problems, and provides a new method for setting neutrons that improves productivity.

Means for Solving the Problems

[0006] The method for setting cores according to this embodiment is a method for setting a plurality of cores in the cavity of a mold, and includes a core combination step of combining a plurality of cores outside the cavity, a negative pressure adsorption step of negatively pressure adsorbing the combined plurality of cores, and a positioning fitting step of fitting a plurality of core fitting parts for determining the positions of the negatively pressure adsorbed plurality of cores to a plurality of mold fitting parts corresponding to the plurality of core fitting parts in the mold. With such a configuration, positioning by a clamping mechanism can be made unnecessary.

[0007] In the above method for setting cores, in the negative pressure adsorption step, a portion of the water glass film formed on at least a part of the surface of the core may be negatively pressure adsorbed. With such a configuration, the degree of vacuum in negative pressure adsorption can be improved, and the conveying ability can be improved.

[0008] In the above method for setting cores, in the core combination step, the plurality of cores include a first core and a second core, and when the first core fitting part in the first core is fitted to a first mold fitting part corresponding to the first core fitting part and then the second core fitting part in the second core is fitted to a second mold fitting part corresponding to the second core fitting part, the first core and the second core may include the first core and the second core having portions that interfere with each other. With such a configuration, interference when arranging the cores in the cavity can be suppressed.

Advantages of the Invention

[0009] According to this embodiment, positioning by a clamping mechanism can be made unnecessary.

Brief Description of the Drawings

[0010]

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Mode for Carrying Out the Invention

[0011] Hereinafter, the present invention will be described through embodiments of the invention, but the invention according to the claims is not limited to the following embodiments. Also, not all of the configurations described in the embodiments are essential as means for solving the problems. For clarity of explanation, the following description and drawings have been appropriately omitted and simplified. In each drawing, the same elements are denoted by the same reference numerals, and duplicate explanations are omitted as necessary.

[0012] Before explaining the method for setting neutrons in the embodiment, the method for setting neutrons according to the comparative example will be explained. This will make the method for setting neutrons in the embodiment clearer.

[0013] (Comparative Example) FIG. 1 is a diagram illustrating a mold and a plurality of cores in a method for setting cores according to a comparative example. As shown in FIG. 1, a mold 90 has a cavity 91 formed therein. The mold 90 also includes mating portions 92a, 92b, 92c, 92d, 92e (collectively referred to as mating portions 92a to 92e). Five mating portions 92a to 92e are shown in the figure, but the number of mating portions 92a to 92e is not limited to five and may be changed according to the number of mating portions formed on the cores.

[0014] A plurality of cores 110, 120, 130, 140, 150 (collectively referred to as cores 110 to 150) are set in the cavity 91. Five cores 110 to 150 are shown in the figure, but the number of cores 110 to 150 is not limited to five. The plurality of cores 110 to 150 may include, for example, a cam case core for forming inside a cam case, a water jacket core, an exhaust port core, and an intake port core. For convenience of explanation, as an example, core 110 will be described as cam case core 110, core 120 as water jacket core 120, core 130 as exhaust port core 130, core 140 as exhaust port core 140, and core 150 as intake port core 150. Note that cam case core 110, water jacket core 120, exhaust port core 130, exhaust port core 140, and intake port core 150 may also be simply referred to as core 110, core 120, core 130, core 140, and core 150, respectively.

[0015] Note that, to make each component in the figure clear, the cross-section of the mold 90 is shown by hatching, while the cores 110 to 150 are not necessarily shown by hatching in cross-section and may be shown by hatching on the surface. The same applies to the following figures.

[0016] The core 110 in the cam case includes a main body portion 111 and a fitting portion 112. The core 120 in the water jacket includes a main body portion 121 and a fitting portion 122. The core 130 of the exhaust port includes a main body portion 131 and a fitting portion 132. The core 140 of the exhaust port includes a main body portion 141 and a fitting portion 142. The core 150 of the intake port includes a main body portion 151 and a fitting portion 152.

[0017] The fitting portion 112 of the core 110 in the cam case fits with the fitting portion 92a of the mold 90. For example, the fitting portion 112 is convex and the fitting portion 92a is concave. Similarly, for the following mutually fitting portions, one may be convex and the other may be concave. By fitting the fitting portion 112 with the fitting portion 92a, the positioning of the core 110 can be achieved.

[0018] The fitting portion 122 of the core 120 in the water jacket fits with the fitting portion 92b of the mold 90. By fitting the fitting portion 122 with the fitting portion 92b, the positioning of the core 120 can be achieved. The fitting portion 132 of the core 130 of the exhaust port fits with the fitting portion 92c of the mold 90. By fitting the fitting portion 132 with the fitting portion 92c, the positioning of the core 130 can be achieved.

[0019] The fitting portion 142 of the core 140 of the exhaust port fits with the fitting portion 92d of the mold 90. By fitting the fitting portion 142 with the fitting portion 92d, the positioning of the core 140 can be achieved. The fitting portion 152 of the core 150 of the intake port fits with the fitting portion 92e of the mold 90. By fitting the fitting portion 152 with the fitting portion 92e, the positioning of the core 150 can be achieved.

[0020] Next, the method for setting the cores 110 to 150 according to the comparative example will be described. First, the core 110 in the cam case, the core 120 in the water jacket, and the core 130 of the exhaust port are arranged inside the cavity 91 formed in the mold 90. When arranging each of the cores 110 to 130, the fitting portion 112 of the core 110, the fitting portion 122 of the core 120, and the fitting portion 132 of the core 130 are respectively fitted with the fitting portions 92a, 92b, and 92c of the mold 90.

[0021] Next, the exhaust port insert 140 and the intake port insert 150 are arranged inside the cavity 91. When arranging the exhaust port insert 140 and the intake port insert 150, the mating parts 142 of the exhaust port insert 140 and the mating parts 152 of the intake port insert 150 are mated with the mating parts 92d and 92e of the mold 90. In the comparative example, when arranging the exhaust port insert 140 and the intake port insert 150 inside the cavity 91, the exhaust port inserts 130 and 140 have interfering portions 160 and 161 with each other. Therefore, the interfering portions 160 and 161 are cut in advance. Thus, in the comparative example, it is necessary to cut a part of the inserts 110 to 150, and there are significant design constraints. Therefore, it may impair the influence on the insert shape and the cooling function of the mold 90.

[0022] (Embodiment 1) Next, a method for setting the inserts according to Embodiment 1 will be described. The method for setting the inserts in this embodiment is a method for setting a plurality of inserts in the cavity 91 of the mold 90. First, the mold 90 and the plurality of inserts will be described. FIG. 2 is a diagram illustrating the mold and the plurality of inserts in the method for setting the inserts according to Embodiment 1. As shown in FIG. 2, the mold 90 has a cavity 91 formed therein, similar to the comparative example. Further, the mold 90 includes mating parts 92a, 92b, 92c, 92d, and 92e. The fact that the mating parts are collectively referred to as mating parts 92a to 92e and that the number of mating parts 92a to 92e is not limited to five and may be changed according to the number of mating parts formed on the insert is the same as in the comparative example.

[0023] Inside the cavity 91, a plurality of core members 10, 20, 30, 40, 50 (the core members are collectively referred to as core members 10 to 50) are set. In the figure, five core members 10 to 50 are shown, but the number of core members 10 to 50 is not limited to five. The plurality of core members 10 to 50 may include, for example, any one of a cam case core member forming inside a cam case, a water jacket core member, an exhaust port core member, and an intake port core member. For the convenience of explanation, as an example, the core member 10 will be described as the cam case core member 10, the core member 20 as the water jacket core member 20, the core member 30 as the exhaust port core member 30, the core member 40 as the exhaust port core member 40, and the core member 50 as the intake port core member 50. In addition, they may simply be referred to as core members 10 to 50. Also, when referring to core members 10 to 50, it may refer to all of core members 10 to 50 or at least any one of core members 10 to 50.

[0024] The cam case core member 10 includes a main body portion 11 and a fitting portion 12. The water jacket core member 20 includes a main body portion 21 and a fitting portion 22. The exhaust port core member 30 includes a main body portion 31 and a fitting portion 32. The exhaust port core member 40 includes a main body portion 41 and a fitting portion 42. The intake port core member 50 includes a main body portion 51 and a fitting portion 52.

[0025] The fitting portion 12 of the cam case core member 10 fits with the fitting portion 92a of the mold 90. For example, the fitting portion 12 is convex and the fitting portion 92a is concave, which is the same as in the comparative example. By fitting the fitting portion 12 with the fitting portion 92a, the positioning of the core member 10 can be achieved. The fitting portion 22 of the water jacket core member 20 fits with the fitting portion 92b of the mold 90. By fitting the fitting portion 22 with the fitting portion 92b, the positioning of the core member 20 can be achieved.

[0026] The mating portion 32 of the exhaust port insert 30 mates with the mating portion 92c of the mold 90. By mating the mating portion 32 with the mating portion 92c, the insert 30 can be positioned. The mating portion 42 of the exhaust port insert 40 mates with the mating portion 92d of the mold 90. By mating the mating portion 42 with the mating portion 92d, the insert 40 can be positioned. The mating portion 52 of the intake port insert 50 mates with the mating portion 92e of the mold 90. By mating the mating portion 52 with the mating portion 92e, the insert 50 can be positioned.

[0027] Next, a method for setting the inserts 20 to 60 according to the present embodiment will be described. FIG. 3 is a flowchart illustrating a method for setting the inserts according to Embodiment 1. As shown in FIG. 3, the method for setting the inserts in the present embodiment includes an insert combination step S11, a negative pressure adsorption step S12, and a positioning and mating step S13. Hereinafter, each step will be described.

[0028] <Insert combination step> First, in the insert combination step S11, a plurality of inserts 30, 40, and 50 are combined outside the cavity 91 of the mold 90.

[0029] In the comparative example, after the exhaust port insert 130 is disposed inside the cavity 91, the exhaust port insert 140 is disposed inside the cavity 91. Specifically, after the mating portion 132 of the exhaust port insert 130 is mated with the mating portion 92c corresponding to the mating portion 132, the mating portion 142 of the exhaust port insert 140 is mated with the mating portion 92d corresponding to the mating portion 142.

[0030] When the exhaust port insert 140 is disposed inside the cavity 91, the exhaust port inserts 130 and 140 have interfering portions 160 and 161 with each other, but the interfering portions 160 and 161 are cut in advance.

[0031] In the present embodiment, before arranging the exhaust port insert 30 inside the cavity 91, the exhaust port insert 30 and the exhaust port insert 40 are combined outside the cavity 91. Here, the exhaust port insert 30 and the exhaust port insert 40 have the following shapes. That is, when the fitting portion 32 of the exhaust port insert 30 is fitted to the fitting portion 92c corresponding to the fitting portion 32, and then the fitting portion 42 of the exhaust port insert 40 is fitted to the fitting portion 92d corresponding to the fitting portion 42, the exhaust port insert 30 and the exhaust port insert 40 have portions that interfere with each other. In such a case, in the comparative example, the interfering portions 160 and 161 are cut.

[0032] On the other hand, in the present embodiment, before fitting the fitting portion 32 of the exhaust port insert 30 and the fitting portion 42 of the exhaust port insert 40 to the fitting portions 92c and 92d of the mold 90, the exhaust port inserts 30 and 40 are combined outside the cavity 91. Therefore, the exhaust port insert 30 and the exhaust port insert 40 can be combined at a location with fewer combination constraints. As a result, it is not necessary to cut the interfering portions 160 and 161, and the design constraints can be reduced.

[0033] Thus, in the present embodiment, in the insert combination step S11, the plurality of inserts 10 to 50 may include a first insert (for example, the exhaust port insert 30) and a second insert (for example, the exhaust port insert 40), and after fitting the first insert fitting portion (fitting portion 32) of the first insert to the first mold fitting portion (fitting portion 92c) corresponding to the first insert fitting portion, when fitting the second insert fitting portion (fitting portion 42) of the second insert to the second mold fitting portion (fitting portion 92d) corresponding to the second insert fitting portion, the first insert and the second insert may include the first insert and the second insert having portions that interfere with each other.

[0034] <Negative pressure adsorption step> Next, in the negative pressure adsorption step S12, a plurality of cores 30, 40, and 50 combined outside the cavity 91 are negatively pressure adsorbed. For example, as shown in FIG. 2, a plurality of cores 30, 40, and 50 are negatively pressure adsorbed by a plurality of adsorption pads 82. FIG. 4 is a diagram illustrating a vacuum generator according to Embodiment 1. As shown in FIG. 4, the vacuum generator 80 includes a vacuum generator 81, an adsorption pad 82, and a tube 83. The adsorption pad 82 is connected to the vacuum generator 81 via the tube 83. In the present embodiment, the cores 30, 40, and 50 are gripped by the adsorption pad 82.

[0035] FIG. 5 is a diagram illustrating the principle of the vacuum generator 81 according to Embodiment 1. As shown in FIG. 5, the vacuum generator 81 generates a vacuum (strictly including not only a vacuum but also a reduced pressure state) by feeding compressed air 84. The compressed air is throttled by a nozzle 85, discharged at high speed, and flows into a diffuser 86. The diffuser 86 is tubular, with compressed air being fed in from one end and discharged from the other end. A hole 87 is opened on the side surface of the diffuser 86. The hole 87 of the diffuser 86 is connected to the space between the adsorption pad 82 and the cores 30, 40, and 50 via a tube 83 (not shown).

[0036] When the compressed air 84 throttled by the nozzle 85 is ejected from the diffuser 86 at high speed, the pressure inside the diffuser 86 decreases and a vacuum is generated. As a result, the space between the adsorption pad 82 and the cores 30, 40, and 50 becomes a vacuum. Therefore, the adsorption pad 82 can grip the cores 30, 40, and 50. In order to obtain a high-speed jet flow and a high degree of vacuum, it has a structure including a nozzle 85 and a diffuser 86. Due to the differences in these shapes and dimensions, the achievable degree of vacuum, the suction flow rate, and the consumption flow rate are determined. Specifically, the degree of vacuum and the adsorption force change depending on the adsorption pad, and also change depending on the configuration and shape of the cores. Therefore, if the manufacturing methods of the adsorption pad and the cores change, the values of the degree of vacuum and the adsorption force will change.

[0037] FIG. 6 is a diagram illustrating any one of the cores 10 to 50 according to Embodiment 1. FIG. 7 is a cross-sectional view illustrating any one of the cores 10 to 50 according to Embodiment 1, showing the cross-section taken along line VII-VII of FIG. 6. As shown in FIGS. 6 and 7, in the present embodiment, for example, cores 10 to 50 having a water glass film 70 formed on the surface are used. The cores 10 to 50 with the water glass film 70 formed thereon are referred to as core CSCORE in the present embodiment. The core CSCORE is obtained by solidifying foamed sand, which is produced by mixing sand, a surfactant, and water with water glass as a binder, stirring, and kneading, in a mold. The sand may be natural sand or artificial sand. Water glass is a mixture containing sodium oxide (Na 2 O) and silicon dioxide (SiO 2 ).

[0038] FIGS. 8(a) to 8(c) are schematic diagrams illustrating cross-sections of the core and the adsorption pad 82 according to Embodiment 1. (a) shows a cross-section of the laminated core 3D formed by a 3D printer, (b) shows a cross-section of the shell core SH, and (c) shows a cross-section of the core CSCORE.

[0039] As shown in FIG. 8(a), in the laminated core 3D, the unevenness on the surface of the lamination trace is large. Therefore, when the laminated core 3D is gripped by the adsorption pad 82, air leaks from the unevenness between the adsorption pad 82 and the laminated core 3D, making it difficult to increase the degree of vacuum. For this reason, it is necessary to treat the unevenness on the surface of the laminated core 3D, such as by coating with a coating agent.

[0040] As shown in FIG. 8(b), in the shell core SH, the surface unevenness is small. However, since air leaks between the sands, when the shell core SH is gripped by the adsorption pad 82, it is difficult to increase the degree of vacuum between the adsorption pad 82 and the shell core SH. Therefore, it is necessary to take measures such as coating the surface of the shell core SH with a coating agent CO or increasing the diameter of the adsorption pad 82 to increase the degree of vacuum.

[0041] Thus, in the case of the laminated neutron 3D and the shell neutron SH, it is necessary to increase the diameter of the coating and / or the adsorption pad 82. When performing the coating, the coating agent CO used for the coating may have an adverse effect on the regeneration treatment of the neutron sand. In addition, increasing the diameter of the adsorption pad 82 requires a large flat surface on the surface of the neutrons 10 to 50 as the adsorption surface of the adsorption pad 82, which will restrict the design of the neutrons 10 to 50. Therefore, the laminated neutron 3D and the shell neutron SH can only be used for simple shapes such as intake port neutrons or shapes with many planes.

[0042] On the other hand, as shown in Fig. 8(c), the neutron CSCORE of the present embodiment has a water glass film 70 on its surface. The water glass film 70 makes it difficult for air to leak between the adsorption pad 82 and the neutron CSCORE, and the degree of vacuum can be increased. Therefore, the coating agent CO can be dispensed with. In addition, the diameter of the adsorption pad 82 can be reduced, and the constraints on the design of the neutrons 10 to 50 can be reduced. Moreover, since the adsorption force is large, it is possible to carry a large number and large-sized neutrons 10 to 50 by negative pressure adsorption.

[0043] Fig. 9 is a graph illustrating the adsorption force required to grip the neutrons 10 to 50 according to Embodiment 1. The horizontal axis represents the degree of vacuum between the neutrons 10 to 50 and the adsorption pad 82, and the vertical axis represents the adsorption force. As shown in Fig. 9, since the measured values and the calculated values in the bellows type B almost coincide, it is considered that the measured values and the calculated values in the bellows type A also coincide. And in any case, when the degree of vacuum is increased, the adsorption force becomes larger.

[0044] For example, as shown in Fig. 9, the degree of vacuum between the laminated neutron 3D, the shell neutron SH, and the neutron CSCORE and the adsorption pad 82 when the valve of the vacuum generator 80 is fully opened increases in this order. That is, in the case of the neutron CSCORE, the adsorption force can be made larger than in the case of the laminated neutron 3D and the shell neutron SH. Thus, the neutron CSCORE formed with the water glass film 70 can improve the degree of vacuum between it and the adsorption pad 82 and improve the adsorption force.

[0045] As shown in FIG. 2, a plurality of cores 30 to 50 are gripped by a plurality of suction pads 82. The suction pad 82 preferably adsorbs a portion where the water glass film 70 is formed on the surface.

[0046] Thus, in the present embodiment, in the negative pressure adsorption step, a portion of the water glass film formed on at least a part of the surface of the core CSCORE is negatively pressure adsorbed. In the case of the core CSCORE, since the degree of vacuum between the core CSCORE and the suction pad 82 can be increased, the adsorption surface of the suction pad 82 can be reduced. Thereby, it can be applied to a core having a complex shape with few flat surfaces such as the water jacket core 20. In addition, the coating agent CO can be made unnecessary. Furthermore, the design constraints for securing a flat surface in the core CSCORE can be reduced.

[0047] <Positioning mating step> Next, in the positioning mating step S13, a plurality of mating portions 32 to 52 for determining the positions of the plurality of cores 30 to 50 negatively pressure adsorbed are mated with a plurality of mating portions 92c to 92e corresponding to the plurality of mating portions 32 to 52. In this way, the plurality of cores 30 to 50 can be set in the cavity 91 of the mold 90.

[0048] Next, the effects of the present embodiment will be described. The method for setting the core of the present embodiment positions by negatively pressure adsorbing and gripping a plurality of cores 15 combined outside the cavity 91 and mating them with the mating portions 92a to 92e of the mold 90. Therefore, positioning by the clamping mechanism can be made unnecessary.

[0049] In addition, since the cores 10 to 50 having the water glass film 70 formed on the surface are negatively pressure adsorbed, the adsorption force for adsorbing the cores 10 to 50 can be improved. Therefore, even in the case of cores 10 to 50 having few flat surfaces, such as cores 10 to 50 having a complex shape, they can be adsorbed.

[0050] Since a plurality of cores 10 to 50 are combined outside the cavity 91 and then set in the mold 90, even if there are interfering portions between the cores 10 to 50 that would interfere when individually set in the mold 90, interference can be avoided. Therefore, the degree of freedom in designing the cores 10 to 50 can be improved. As a result, various properties of the casting, such as the cooling performance of the water jacket formed by the water jacket core, can be improved.

[0051] Note that the present invention is not limited to the above-described embodiments, and can be appropriately modified without departing from the spirit. For example, a combination of the configurations of Embodiment 1 is also included in the scope of the technical idea of this embodiment.

Explanation of Reference Numerals

[0052] 10, 20, 30, 40, 50 Cores 11, 21, 31, 41, 51 Main Body Parts 12, 22, 32, 42, 52 Fitting Parts 70 Water Glass Film 80 Vacuum Generation Device 81 Vacuum Generator 82 Suction Pad 83 Tube 84 Compressed Air 85 Nozzle 86 Diffuser 87 Hole 90 Mold 91 Cavity 92a, 92b, 92c, 92d, 92e Fitting Parts 110, 120, 130, 140, 150 Cores 111, 121, 131, 141, 151 Main Body Parts 112, 122, 132, 142, 152 Fitting Parts 160, 161 Interfering Portions

Claims

1. A method for setting a plurality of cores in a cavity of a mold, comprising: a core combination step of combining a plurality of cores outside the cavity; a negative pressure adsorption step of subjecting the combined plurality of cores to negative pressure adsorption; a positioning engagement step of engaging a plurality of core engagement portions for determining the positions of the plurality of cores subjected to negative pressure adsorption with a plurality of mold engagement portions corresponding to the plurality of core engagement portions in the mold; wherein in the negative pressure adsorption step, at least a part of the water glass film formed on at least a part of the surface of the core is subjected to negative pressure adsorption. A method for setting a core.

2. In the core combination step, the plurality of cores include a first core and a second core, when the first core engagement portion in the first core is engaged with the first mold engagement portion corresponding to the first core engagement portion, and then the second core engagement portion in the second core is engaged with the second mold engagement portion corresponding to the second core engagement portion, the first core and the second core include the first core and the second core having portions interfering with each other. The method for setting a core according to Claim 1.

3. A method for setting a plurality of cores in a cavity of a mold, comprising: a core combination step of combining a plurality of cores outside the cavity; a negative pressure adsorption step of subjecting the combined plurality of cores to negative pressure adsorption; a positioning engagement step of engaging a plurality of core engagement portions for determining the positions of the plurality of cores subjected to negative pressure adsorption with a plurality of mold engagement portions corresponding to the plurality of core engagement portions in the mold; wherein in the core combination step, the plurality of cores include a first core and a second core, when the first core engagement portion in the first core is engaged with the first mold engagement portion corresponding to the first core engagement portion, and then the second core engagement portion in the second core is engaged with the second mold engagement portion corresponding to the second core engagement portion, the first core and the second core include the first core and the second core having portions interfering with each other. A method for setting a core.

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