Casting apparatus and control method thereof

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 Art

[0002] Patent Document 1 discloses a die casting method in which a coating material is applied to the molten metal pouring surface of a die to form a coated mold, and molten metal is poured onto the molten metal pouring surface covered with the coated mold.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the method disclosed in Patent Document 1, when a part of the coated mold is damaged or worn due to repeated casting, the shape of the damaged or worn part of the coated mold is transferred to the rough material, so there is a problem that high-quality castings cannot be produced.

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

Means for Solving the Problems

[0006] The casting apparatus according to this disclosure comprises a mold on which a mold coating is formed on the molten metal pouring surface, a molten metal pouring unit for pouring molten metal into the molten metal pouring surface of the mold on which the mold coating is formed, a determination unit for determining the quality of the surface shape of the casting formed by the mold, and a control unit for adjusting the mold release speed based on the determination result by the determination unit. If signs of quality deterioration in the surface shape of the casting are observed in this casting apparatus due to defects in the mold coating formed on the molten metal pouring surface of the mold, for example, the mold release speed is slowed down to suppress the deterioration of the quality of the surface shape of the casting. As a result, this casting apparatus can continue to cast high-quality castings.

[0007] The casting apparatus control method according to this disclosure comprises a mold on which a mold coating is formed on the molten metal pouring surface, and a molten metal pouring section for pouring molten metal into the molten metal pouring surface of the mold on which the mold coating is formed. The method determines the quality of the surface shape of the casting formed by the mold and adjusts the mold release speed for the next casting to be formed based on the determination result. If signs of deterioration in the quality of the surface shape of the casting are observed due to defects in the mold coating formed on the molten metal pouring surface of the mold, this casting apparatus control method suppresses deterioration in the quality of the surface shape of the casting by, for example, slowing down the mold release speed. As a result, this casting apparatus control method can continue to cast high-quality castings. [Effects of the Invention]

[0008] This disclosure provides a casting apparatus capable of casting high-quality castings, and a control method thereof. [Brief explanation of the drawing]

[0009] [Figure 1] This is a block diagram showing an example of the configuration of a casting apparatus according to this disclosure. [Figure 2] This figure shows the relationship between the number of casting shots and the actual area of ​​mold peeling. [Figure 3] This figure shows the relationship between the mold peeling area determined by the casting apparatus according to this disclosure using a trained model and the actual mold peeling area. [Figure 4] This figure shows images of the surfaces of multiple castings with different numbers of casting shots. [Figure 5] This figure shows the relationship between the mold release speed and the area of ​​mold coating removal. [Figure 6] This is a flowchart showing the operation of the casting apparatus relating to this disclosure. [Modes for carrying out the invention]

[0010] The present invention will be described below through embodiments, but the claims are not limited to the following embodiments. Furthermore, not all of the configurations described in the embodiments are necessarily essential for solving the problem. For clarity of explanation, the following descriptions and drawings have been omitted and simplified as appropriate. In each drawing, the same elements are denoted by the same reference numerals, and redundant explanations have been omitted where necessary.

[0011] Figure 1 is a block diagram showing an example configuration of the casting apparatus 1 according to this disclosure. The casting apparatus 1 according to this disclosure suppresses deterioration of the surface shape of the casting by slowing down the mold release speed when signs of deterioration in the surface shape of the casting are observed due to defects in the mold coating formed on the molten metal pouring surface of the mold. As a result, the casting apparatus 1 according to this disclosure can continue to cast high-quality castings. This will be explained in detail below.

[0012] As shown in Figure 1, the casting apparatus 1 comprises at least a mold 11, a molten metal input unit 12, a determination unit 13, and a control unit 14.

[0013] A mold coating 101 is formed on the molten metal pouring surface of the mold 11. The mold coating 101 is formed by diluting a mold coating material with water and spraying (applying) it to the molten metal pouring surface of the mold 11 using a spray gun or the like. Examples of mold coating materials include ALO3 and ZnO. The mold coating 101 makes it easier to remove the rough material of the casting 102 formed by the mold 11 from the mold 11 (i.e., improves the release properties of the mold 11) and improves the moisture retention of the mold 11.

[0014] The molten metal inlet section 12 pours (casts) molten metal, such as aluminum, into the molten metal inlet surface of the mold 11 on which the mold coating 101 is formed. The molten metal poured into the mold 11 cools and solidifies inside the mold 11, becoming the raw material for the casting 102, which is formed into the desired shape. The raw material for the casting 102, which has been formed into the desired shape by the mold 11, is removed from the mold 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 taken by a camera or other imaging device.

[0016] Here, if defects or wear occur in the mold coating 101 formed on the molten metal casting surface of the mold 11, the shape of the defective or worn portion of the mold coating 101 is transferred to the raw material. As a result, the surface shape of the portion of the casting 102 corresponding to the defects in the mold coating 101 may differ from the ideal surface shape. Therefore, the determination unit 13 determines that the casting 102 is a good product if the area of ​​the portion of the casting 102 that differs from the ideal surface shape is within an acceptable range, and determines that the casting 102 is a defective product if the area of ​​the portion of the casting 102 that differs from the ideal surface shape is outside an acceptable range. Hereinafter, the area of ​​the casting 102 that differs from the ideal surface shape due to the effects of defects in the mold coating 101 will also be referred to as the mold coating peeling area.

[0017] Further, even when the mold peeling area of the casting 102 is within the allowable range, if it seems to exceed the allowable range or signs of quality deterioration are found in the surface shape of the casting 102, the determination unit 13 determines so. Alternatively, when the degree of increase in the mold peeling area of the casting 102 associated with the increase in the number of casting shots is large compared to the past statistical values, the determination unit 13 may determine that signs of quality deterioration are found in the surface shape of the casting 102. The number of casting shots is the number of times molten metal is poured into the mold 11.

[0018] FIG. 2 is a diagram showing the relationship between the number of casting shots and the mold peeling area. In FIG. 2, the dotted line represents the past statistical values, and the solid line represents the set threshold value.

[0019] As shown in FIG. 2, the larger the number of casting shots, the larger the mold peeling area. Here, if the allowable range of the mold peeling area is 10 mm 2 then the determination unit 13 determines the casting 102 with a mold peeling area of 10 mm 2 or less as a good product, and determines the casting 102 with a mold peeling area exceeding 10 mm 2 as a defective product. Further, even when the mold peeling area is within the allowable range, if it seems to exceed the allowable range, for example, when it reaches 8 mm 2 the determination unit 13 determines that signs of quality deterioration are found in the surface shape of the casting 102. Furthermore, when the degree of increase in the mold peeling area of the casting 102 associated with the increase in the number of casting shots is large compared to the past statistical values, for example, when it exceeds the set threshold value (solid line), the determination unit 13 may determine that signs of quality deterioration are found in the surface shape of the casting 102.

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

[0021] Figure 3 shows the relationship between the mold peeling area identified by the determination unit 13 using a trained model and the actual mold peeling area. In Figure 3, the mold peeling area identified by the determination unit 13 using a trained model is represented in pixels. Figure 4 shows images of the surfaces of multiple castings 102 with different numbers of casting shots. The top image in Figure 4 shows the image of the casting 102 after the second shot, the middle image in Figure 4 shows the image of the casting 102 after the 55th shot, and the bottom image in Figure 4 shows the image of the casting 102 after the 103rd shot.

[0022] As shown in Figures 3 and 4, there is a correlation between the mold peeling area identified by the determination unit 13 using the trained model and the actual mold peeling area. In other words, the determination unit 13 can accurately identify the mold peeling area of ​​the casting 102 by using the trained model.

[0023] The control unit 14 adjusts the mold release speed of the mold 11 based on the determination result from the determination unit 13. Specifically, if the determination unit 13 determines that there are signs of quality deterioration in the surface shape of the casting 102, the control unit 14 slows down the mold release speed of the mold 11. Alternatively, the control unit 14 may slow down the mold release 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 mold release speed of the mold 11, the more the mold coating peeling off of the casting 102 is suppressed.

[0024] Figure 5 shows the relationship between the demolding speed and the area of ​​mold coating peeling. As shown in Figure 5, the slower the demolding speed, the smaller the area of ​​mold coating peeling on the casting 102. Therefore, if the casting apparatus 1 observes signs of quality deterioration in the surface shape of the casting 102, it can suppress quality deterioration of the casting 102 by slowing the demolding speed of the mold 11 to suppress mold coating peeling. However, if there are no signs of quality deterioration in the surface shape of the casting 102, the casting apparatus 1 can simply increase the demolding speed of the mold 11 to cast the casting 102 efficiently.

[0025] Furthermore, if the determination unit 13 determines that the casting 102 is defective or that there are signs of quality deterioration in the surface shape of the casting 102, the control unit 14 may issue a notification prompting the repair of the mold coating 101. The notification prompting the repair of the mold coating 101 may be output as audio via a speaker or displayed on a monitor. Upon receiving this notification, the worker can repair the mold coating 101. If the casting apparatus 1 is equipped with a function to automatically repair the mold coating 101, the control unit 14 may be configured to instruct that function to perform the repair.

[0026] Next, we will explain the operation of the casting apparatus 1 using Figure 6. Figure 6 is a flowchart showing the operation of the casting apparatus 1.

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

[0028] Subsequently, the casting apparatus 1 pours molten metal, such as aluminum, into the molten metal pouring surface of the mold 11 on which the mold coating 101 has been formed (step S103). The molten metal poured into the mold 11 cools and solidifies inside the mold 11, becoming the raw material for the casting 102 formed into the desired shape.

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

[0030] Subsequently, the casting apparatus 1 determines the quality of the surface shape of the casting 102 formed by the mold 11 using a trained model generated by machine learning using, for example, images of the surfaces of multiple castings (step S106).

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

[0032] Furthermore, the casting apparatus 1 determines that there are signs of quality deterioration in the surface shape of the casting 102 if the area of ​​mold peeling on the casting 102 is within the acceptable range, or if it appears likely to exceed the acceptable range. In addition, the casting apparatus 1 may determine that there are signs of quality deterioration in the surface shape of the casting 102 if the degree of increase in the area of ​​mold peeling on the casting 102 due to the increase in the number of casting shots is greater than that of past statistical values.

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

[0034] Furthermore, the casting apparatus 1 issues instructions to repair the mold coating 101 as necessary based on the judgment result (step S108). Specifically, if the casting apparatus 1 determines that the casting 102 is defective or that there are signs of quality deterioration in the surface shape of the casting 102, it issues a notification prompting the repair of the mold coating 101. The notification prompting the repair of the mold coating 101 is output as audio via a speaker or displayed on a monitor. Upon receiving this notification, the worker can then repair the mold coating 101.

[0035] Subsequently, if the casting apparatus 1 has not performed the predetermined number of shots, it returns to the process in step S103 (NO in step S109), and if it has performed the predetermined number of shots, it terminates the casting process (YES in step S109).

[0036] Thus, the casting apparatus 1 according to this disclosure suppresses deterioration of the surface shape of the casting 102 by slowing down the demolding speed of the mold 11 when signs of deterioration in the surface shape of the casting 102 are observed due to defects in the mold coating 101 formed on the molten metal pouring surface of the mold 11. As a result, the casting apparatus 1 according to this disclosure can continue to cast high-quality castings 102.

[0037] Furthermore, this disclosure can be realized by having a CPU (Central Processing Unit) execute a computer program to perform part or all of the processing of the casting apparatus 1.

[0038] The program described above includes, when loaded into a computer, a set of instructions (or software code) for causing the computer to perform one or more of the functions described in the embodiments. The program may be stored in a non-temporary computer-readable medium or a physical storage medium. Examples, but not limited to, include RAM (Random-Access Memory), ROM (Read-Only Memory), flash memory, SSD (Solid-State Drive), or other memory technologies, CD-ROM, DVD (Digital Versatile Disc), Blu-ray® disc, or other optical disc storage, magnetic cassette, magnetic tape, magnetic disk storage, or other magnetic storage devices. The program may be transmitted over a temporary computer-readable medium or a communication medium. Examples, but not limited to, include temporary computer-readable medium or a communication medium that includes electrically, optically, acoustically, or otherwise propagating signals.

[0039] Some or all of the above embodiments may also be described as follows, but are not limited to these.

[0040] (Note 1) A mold in which a mold coating is formed on the molten metal pouring surface, A molten metal inlet for pouring molten metal into the molten metal pouring surface of the mold on which the aforementioned mold coating is formed, A control program that causes a computer to execute control processing for a casting apparatus, comprising: A process for determining the quality of the surface shape of the casting formed by the aforementioned mold, Based on the determination result, a process is performed to adjust the mold release speed for the next casting to be formed, A control program that instructs a computer to execute a command. [Explanation of Symbols]

[0041] 1. Casting apparatus 11 molds 12 Molten metal inlet section 13 Judgment section 14 Control Unit 101 Painting mold 102 Castings

Claims

1. A mold in which a mold coating is formed on the molten metal pouring surface, A molten metal inlet for pouring molten metal into the molten metal pouring surface of the mold on which the aforementioned mold coating is formed, A determination unit for determining the quality of the surface shape of the casting formed by the mold, A control unit that adjusts the mold release speed based on the determination result from the determination unit, A casting apparatus comprising, If the determination unit determines that there are signs of quality deterioration in the surface shape of the casting, the control unit slows down the mold release speed. Casting apparatus.

2. A mold in which a mold coating is formed on the molten metal pouring surface, A molten metal inlet for pouring molten metal into the molten metal pouring surface of the mold on which the aforementioned mold coating is formed, A method for controlling a casting apparatus, comprising: The quality of the surface shape of the casting formed by the aforementioned mold is determined, Based on the judgment result, the mold release speed for the next casting to be formed is adjusted. In adjusting the mold release speed for the casting to be formed next, if it is determined in the quality assessment that there are signs of quality deterioration in the surface shape of the casting, the mold release speed is slowed down. A method for controlling a casting apparatus.

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