Molding system

Abstract

A molding system MS has: a die casting machine 1 that injects, into a mold 101, a molten metal ML in an injection sleeve 107; and a hot-liquid supply device 55 that supplies the molten metal ML to the injection sleeve 107. The injection sleeve 107 has an end on the side opposite to the mold 101 that is positioned downward with respect to the end on the mold 101 side. The hot-liquid supply device 55 has: a metering chamber R1 that stores the molten metal ML; and a valve body 63 that moves between an inflow position and an outflow position. At the inflow position, the valve body 63 allows flow from a furnace 53 into the metering chamber R1 and inhibits flow from the metering chamber R1 to the injection sleeve 107 of the die casting machine 1. At the outflow position, the valve body 63 inhibits flow from the furnace 53 to the metering chamber R1 and allows flow from the metering chamber R1 to the injection sleeve 107.

Description

Molding System

[0001] The present disclosure relates to a molding system that includes a molding machine such as a die-casting machine and a molten metal supply device that supplies a molten (liquid) metal material (hereinafter, sometimes referred to as "molten metal") to the molding machine.

[0002] Vertical injection die casting machines (e.g., horizontal clamping vertical injection) are known (see, for example, Patent Documents 1 to 7 listed below). In vertical injection, an injection sleeve that leads into the mold from below extends vertically (e.g., vertically), and the molten metal in the injection sleeve is forced upward from below, filling the mold. In horizontal clamping die casting, the molds (fixed mold and movable mold) are opened and closed laterally (e.g., horizontally).

[0003] BACKGROUND ART In a molding system including a vertical injection die-casting machine and a molten metal supply device that supplies molten metal to the die-casting machine, various modes of supplying molten metal to an injection sleeve have been proposed.

[0004] For example, in Patent Documents 1 and 2, molten metal is supplied via a feed pipe connected to an injection sleeve. In Patent Document 3, molten metal is pushed into the above-mentioned feed pipe with a plunger. In Patent Document 4, a trough is placed above the injection sleeve with the injection sleeve spaced downward from the mold, and molten metal is poured into the trough with a ladle. In Patent Documents 5 to 7, molten metal is transferred to the above-mentioned feed pipe with an electromagnetic pump. Patent Document 8, although not related to vertical injection, discloses a method using a feed pipe and an electromagnetic pump.

[0005] JP 9-108806, JP 6-15860, JP 2004-344975, 2012-148323, JP 7-51828, JP 9-150254, 2000-15417, JP 6-126414

[0006] A molding system that makes it easier to improve the quality of molded products is desired.

[0007] A molding system according to one aspect of the present disclosure includes a molding machine that injects molten metal from an injection sleeve into a mold, and a water heater that supplies molten metal to the injection sleeve. The injection sleeve has an end opposite the mold that is positioned lower than the end facing the mold. The water heater includes a measuring chamber that accommodates molten metal, and a valve body. The valve body moves between an inlet position and an outlet position. The inlet position is a position that allows flow from a furnace to the measuring chamber and prohibits flow from the measuring chamber to the injection sleeve. The outlet position is a position that prohibits flow from the furnace to the measuring chamber and allows flow from the measuring chamber to the injection sleeve.

[0008] According to the above configuration, for example, it is easy to improve the quality of the molded product.

[0009] 1 is a side view showing the configuration of a main part of a die-casting machine according to an embodiment. Figures 2(a), 2(b), and 2(c) are perspective views showing the configuration of an injection sleeve in the die-casting machine of Figure 1. Figures 3(a), 3(b), and 3(c) are cross-sectional views of a mold and its surroundings in the die-casting machine of Figure 1. Figures 4(a) and 4(b) are views of a fixed mold and its surroundings in the die-casting machine of Figure 1, viewed from the movable mold. Figures 5(a), 5(b), and 5(c) are perspective views showing the configuration of an injection sleeve according to another example. A flowchart showing the procedure of a molding process performed by the die-casting machine of Figure 1. A cross-sectional view showing the configuration of a hot water supply system according to an embodiment. Figures 8(a), 8(b), and 8(c) are cross-sectional views illustrating the operation of a valve mechanism according to a first aspect of the hot water supply system of Figure 7. Figures 9(a), 9(b), and 9(c) are cross-sectional views illustrating the operation of a valve mechanism according to a second aspect of the hot water supply system of Figure 7. 10 is a perspective view showing an example of a valve drive unit that drives a valve element. FIG. 11 is a cross-sectional view taken along line XI-XI in FIG. 10. FIG. 12 is a cross-sectional view showing the configuration of a molten metal level sensor according to another example. FIG. 13 is a flowchart showing the procedure of the molten metal supply process executed by the molten metal supply system of FIG. 7. FIG. 14 is a side view of a die-casting machine according to another example.

[0010] For aspects that are described relatively later among the multiple aspects, only differences from the previously described aspects will be described. Matters not specifically mentioned may be considered to be the same as or inferred from the previously described aspects. Furthermore, for the sake of convenience, the same reference numerals may be used to refer to corresponding configurations in multiple aspects, even if there are differences.

[0011] The drawings used in the following description are schematic. Therefore, for example, details may be omitted, or specific shapes and / or dimensions may be exaggerated. Furthermore, the detailed configurations may not match between drawings. However, this does not deny that features such as shapes and / or dimensions may be extracted based on the drawings.

[0012] For convenience, the drawings may be illustrated with a Cartesian coordinate system D1D2D3, and terms such as D1 direction, D2 direction, and D3 direction may be used. The D1 direction and D2 direction are horizontal directions, and the D3 direction is vertical. In the description of the embodiments, unless a contradiction arises, the terms "D1 direction" and "D2 direction" may be replaced with "lateral direction" or "horizontal direction," and the term "D3 direction" may be replaced with "vertical direction," "up-down direction," or "vertical direction."

[0013] The "horizontal direction" used in describing the mold opening / closing direction, etc., includes not only the horizontal direction but also angles inclined at an angle of less than 45° to the horizontal direction. Furthermore, the "vertical direction" used in describing the injection direction, etc., includes not only the vertical direction (the direction of gravity) but also angles inclined at an angle of less than 45° to the vertical direction. Note that the upper limit of the inclination angle in the "horizontal direction" and "vertical direction" may be 30°, 20°, or 10° instead of 45°.

[0014] The term "divided" used in describing the injection sleeve is intended to describe the configuration of the injection sleeve itself, not the manufacturing process of the injection sleeve. For example, when the injection sleeve is said to be divided into a first divided sleeve and a second divided sleeve, it does not mean that the injection sleeve is integrally formed during the manufacturing process and is divided (although it may be manufactured that way). The first divided sleeve and the second divided sleeve may be manufactured separately from the beginning.

[0015] The term "separated" used to describe the multiple split sleeves that make up the injection sleeve refers to the multiple split sleeves moving relative to the cylindrical injection sleeve (the multiple split sleeves being "united"). Therefore, for example, when two split sleeves are said to be separated, they may be partially in contact with each other (they do not need to be completely separated).

[0016] 1 is a side view (partially including a cross-sectional view) showing the configuration of a die-casting machine 1 (a molding machine in a broader sense) included in a molding system MS according to an embodiment. In addition to the die-casting machine 1, the molding system MS also includes, for example, a hot water supply system 51 shown in FIG. 7 , which will be described later.

[0017] The die-casting machine 1 produces a die-cast product (a molded product in a broader concept) by filling a mold 101 with molten metal ML (see FIG. 3( b ); a molding material in a broader concept).

[0018] 3(a) to 3(c) are enlarged views of the die 101 and its surrounding area in FIG. 1, showing different states. As shown in FIGS. 3(b) and 3(c), the die-casting machine 1 is of a vertical injection type. That is, the molten metal ML in the vertically extending injection sleeve 107 is pushed upward by the plunger 109, thereby filling the die 101.

[0019] 7 is a schematic diagram showing a molten metal supply system 51 that supplies the molten metal ML to the injection sleeve 107. The molten metal supply system 51 includes a furnace 53 that holds the molten metal ML, and a molten metal supply device 55 that supplies the molten metal ML held in the furnace 53 to the injection sleeve 107. The molten metal ML flowing out from the molten metal supply pipe 65 of the molten metal supply device 55 is supplied directly or indirectly to the injection sleeve 107.

[0020] The molten metal supply device 55 has a measuring chamber R1 that contains one shot of molten metal ML, and a valve body 63 that controls the inflow and outflow of the molten metal ML in the measuring chamber R1. In the illustrated example, the valve body 63 is formed by the bottom of a container 61 that constitutes the measuring chamber R1.

[0021] The valve element 63 (or, from another perspective, the container 61) moves between an inflow position and an outflow position. The inflow position is the position where the valve element 63 is located in Figure 7, and allows flow from the furnace 53 to the metering chamber R1 while prohibiting flow from the metering chamber R1 to the molten metal supply pipe 65 (or, from another perspective, the injection sleeve 107). The outflow position is the position where the valve element 63 moves to the left from the position in Figure 7, and prohibits flow from the furnace 53 to the metering chamber R1 while allowing flow from the metering chamber R1 to the molten metal supply pipe 65.

[0022] In this configuration, the molten metal ML is supplied from the furnace 53 to the injection sleeve 107 via the measuring chamber R1, which reduces the likelihood of the molten metal ML being oxidized or cooled compared to, for example, a mode in which the molten metal is supplied to the injection sleeve 107 by a ladle. In other words, high-quality molten metal ML can be supplied to the injection sleeve 107. Furthermore, because the amount of molten metal supplied can be adjusted by operating the valve body 63, the amount of molten metal supplied can be adjusted with higher precision compared to, for example, a mode in which the amount of molten metal supplied is adjusted by controlling an electromagnetic pump.

[0023] On the other hand, the injection sleeve 107 is for vertical injection, and the ratio of the volume of the molten metal to the volume of the injection sleeve 107 (sleeve filling rate) is high. Therefore, for example, the probability that the molten metal ML will entrain gas (e.g., air) is low. Because high-quality molten metal ML is supplied in a highly accurate amount to this injection sleeve 107 for vertical injection, the molding system MS as a whole can produce high-quality die-cast products.

[0024] The above is an overview of the molding system MS according to the embodiment. The following will roughly explain the embodiment in the following order: 1. Die-casting machine 1.1. Die-casting machine in general (FIG. 1) 1.2. Injection device in general 1.3. Injection sleeve and sleeve drive unit (FIGS. 2(a) to 4(b)) 1.4. Other examples of injection sleeve (FIGS. 5(a) to 5(c)) 1.5. Gutter and gutter drive unit (FIGS. 1 and 3(a) to 3(c)) 1.6. Operation of die-casting machine (FIG. 6) 2. Hot water supply system 2.1. Hot water supply system in general (FIG. 7) 2.2. Hot water supply device 2.2.1. Hot water supply device in general 2.2.2. Container 2.2.3. Valve 2.2.3.1. Valve mechanism according to the first aspect 2.2.3.2. Valve body according to other examples (Figs. 8(a) to 8(c)) 2.2.3.3. Valve mechanism according to the second embodiment (Figs. 9(a) to 9(c)) 2.2.4. Valve drive unit 2.2.4.1. Valve drive unit in general 2.2.4.2. Example using double cylinder (Figs. 10 and 11) 2.2.5. Molten metal level sensor 2.2.5.1. Molten metal level sensor in general 2.2.5.2. Example using laser displacement sensor (Fig. 12) 2.2.6. Gas pressure circuit 2.2.6.1. Gas pressure circuit in general 2.2.6.2. Configuration related to inert gas supply 2.2.6.3. Configuration related to inert gas suction 2.2.6.4. Other configurations of the gas pressure circuit 2.3. Furnace 2.4. Other configurations of the hot water supply system 2.5. 2.6. Molten metal transfer method, etc. 2.7. Operation of the melt supply system (FIG. 13) 3. Die-casting machine according to another example (FIG. 14) 4. Summary of the embodiment

[0025] (1. Die Casting Machine) (1.1. Die Casting Machines in General) The die casting machine 1 may have various configurations, for example, it may be similar to a known configuration. Note that explanations of configurations and operations that may be known configurations and operations will be omitted as appropriate. The die casting machine 1 illustrated in FIG. 1 is of a horizontal clamping, vertical injection type. That is, the mold opening / closing direction and mold clamping direction are horizontal, and the injection direction is vertical. The type of metal molded by the die casting machine 1 is arbitrary, for example, aluminum or an aluminum alloy.

[0026] The mold 101 is, for example, basically made of metal and includes a fixed mold 103 and a movable mold 105 that moves in the mold opening / closing direction relative to the fixed mold 103. A cavity is formed between the two molds into which the molten metal ML is filled. For convenience, in FIG. 1 and other figures, the cross section of the fixed mold 103 or the movable mold 105 is shown with a single type of hatching. However, these molds may be of a direct engraving type or a nesting type. Furthermore, the fixed mold 103 and the movable mold 105 may be combined with a core or the like. Note that the mold 101 is replaceable by the user, and therefore may be considered either as being separate from or as being part of the die-casting machine 1.

[0027] The die-casting machine 1 has, for example, a machine main body 3 that performs mechanical operations for molding, a controller 5 that controls the operation of the machine main body 3, and an interface 13 that acts as an intermediary between the controller 5 and an operator. The machine main body 3 has, for example, a mold clamping device 7 that opens, closes, and clamps the mold 101, an injection device 9 that injects molten metal into the clamped mold 101, and an extrusion device 11 that extrudes the die-cast product from a fixed mold 103 or a movable mold 105 (movable mold 105 in FIG. 1 ).

[0028] In a molding cycle, the mold clamping unit 7 moves the movable mold 105 toward the fixed mold 103 to close the mold. Furthermore, the mold clamping unit 7 applies a clamping force to the mold 101 according to the extension amount of the tie bars (reference numerals omitted) to clamp the mold. The injection unit 9 injects and fills the cavity of the clamped mold 101 with molten metal. The filled molten metal loses heat to the mold 101, is cooled, and solidifies. In other words, the molten metal becomes a molded product. The mold clamping unit 7 then moves the movable mold 105 away from the fixed mold 103 to open the mold. At this time, or thereafter, the extrusion unit 11 extrudes the molded product from the movable mold 105.

[0029] The mold clamping device 7 may have any configuration. For example, the mold clamping device 7 may be one that performs mold opening / closing and mold clamping using a toggle mechanism (as shown in the example), or may have separate drive mechanisms for mold opening / closing and mold clamping. The drive unit that generates the drive force for mold opening / closing and / or mold clamping may be electric, hydraulic, or a hybrid type that combines both. However, if at least mold opening and closing is achieved by an electric drive unit, the high positioning accuracy facilitates the sliding of the split sleeve in the mold closed state, as described below. The mold clamping device 7 has a fixed die plate 15 that holds the fixed die 103 and a movable die plate 17 that holds the movable die 105.

[0030] The controller 5 may include, for example, a computer (not shown). The computer may include, for example, a central processing unit (CPU), read-only memory (ROM), random access memory (RAM), and an auxiliary storage device (not shown). The CPU executes programs stored in the ROM and / or the auxiliary storage device to configure various functional units that perform various calculations (including control). The controller 5 may also include a logic circuit that executes certain operations, a power supply circuit, or a driver. The controller 5 may be provided in, for example, a control panel (not shown). Part of the controller 5 may also be configured as part of the interface 13. The controller 5 may be integrated into one hardware location or distributed across multiple locations.

[0031] In the above, the controller 5 has been described as a part of the die-casting machine 1. However, the controller 5 may be regarded as a conceptual entity that includes all of the various controllers that control the molding system MS. Furthermore, when focusing on each device included in the molding system MS, the controller 5 may be regarded as a controller for that device. For example, the controller 5 may be regarded as a controller for the injection device 9, the hot water supply system 51, or the hot water supply device 55. The same applies to the interface 13; for example, the interface 13 may be regarded as a component of the molding system MS, the injection device 9, the hot water supply system 51, or the hot water supply device 55.

[0032] The interface 13 may be provided at an appropriate position, and in the illustrated example, is provided on the fixed die plate 15 that holds the fixed die 103 in the mold clamping unit 7. The interface 13 has, for example, an input device (reference numeral omitted) that accepts input operations from an operator, and a display device (reference numeral omitted) that displays images.

[0033] (1.2. Injection Device in General) The injection device 9 has, for example, the following components: Sleeve drive unit 19 (FIG. 4(a)): Drives the injection sleeve 107. Plunger drive unit 21 (FIG. 1): Drives the plunger 109. Gutter drive unit 23 (FIG. 1): Drives the gutter 111, which will be described later.

[0034] As will be described later, gutter 111 and gutter drive unit 23 contribute to supplying hot water to injection sleeve 107. Therefore, unlike the description of the embodiment, gutter 111 and gutter drive unit 23 may be considered as part of hot water supply system 51. In this case, gutter 111 and gutter drive unit 23 may be considered as a device separate from hot water supply device 55, or may be considered as part of hot water supply device 55.

[0035] The injection sleeve 107 and the plunger 109 may be replaced (or may not be replaced) when the mold 101 is replaced, and are consumables. Therefore, they may be considered to be either not part of the molding system MS or part of the molding system MS.

[0036] The gutter 111 can be (but does not have to be) replaced when the mold 101 is replaced. Therefore, the gutter 111 may be considered not to be part of the molding system MS, or may be considered to be part of the molding system MS.

[0037] Depending on the specific aspects (described later), the sleeve drive unit 19 and the gutter drive unit 23 may (but do not have to) be replaced along with replacement of the mold 101. Therefore, unlike the description of the embodiment, they may not be considered as part of the molding system MS.

[0038] The injection device 9 may have other appropriate components in addition to the above-mentioned components. For example, although not shown, the injection device 9 may have a mechanism for raising and lowering the plunger driving unit 21 and a tie rod connected to the plunger driving unit 21 and engaging with the mold 101.

[0039] The plunger 109 and the plunger driver 21 may have the same configuration as known in the art. For example, as shown in FIG. 3A, the plunger 109 has a tip 109a that slides inside the injection sleeve 107 and a rod 109b whose front end is fixed to the tip 109a.

[0040] Furthermore, for example, the plunger driving unit 21 is connected to the rear end of the rod 109b and moves the rod 109b forward and backward. The plunger driving unit 21 may be a hydraulic type (e.g., a hydraulic cylinder), an electric type, or a hybrid type that combines both.

[0041] (1.3. Injection Sleeve and Sleeve Drive Unit) Figures 2(a) to 2(c) are perspective views showing the injection sleeve 107. Figures 2(a), 2(b), and 2(c) correspond to Figures 3(a), 3(b), and 3(c), respectively.

[0042] As shown in Figures 2(a) to 2(c), the injection sleeve 107 includes, for example, three members. Specifically, the injection sleeve 107 is divided in the mold opening / closing direction (direction D1), and includes a first divided sleeve 107a and a second divided sleeve 107b, as indicated by the reference numerals in Figures 2(a) and 2(c). The first divided sleeve 107a is also divided in the vertical direction (the vertical direction from another perspective), and includes a lower divided sleeve 107c and an upper divided sleeve 107d.

[0043] As shown in Figure 3(a), the first split sleeve 107a is supported by one of the fixed die 103 and the movable die 105 (the former in the illustrated example), and the second split sleeve 107b is supported by the other of the fixed die 103 and the movable die 105 (the latter in the illustrated example). Therefore, after the molten metal in the die 101 has solidified, the first split sleeve 107a and the second split sleeve 107b are separated when the die is opened. As a result, when the die-cast product is released from the fixed die 103 and the movable die 105, the biscuit (the solidified portion in the injection sleeve 107) can be released from the first split sleeve 107a and the second split sleeve 107b.

[0044] Either the first split sleeve 107a or the second split sleeve 107b may be provided on the fixed die 103 or the movable die 105. For convenience, the explanation of the embodiment will be based on the illustrated example. The first split sleeve 107a is accompanied by a sleeve drive unit 19 and the like. Therefore, in an aspect in which the first split sleeve 107a is provided on the fixed die 103 as in the illustrated example, for example, there is no need to move the sleeve drive unit 19 together with the movable die 105. As a result, the energy required to drive the movable die plate 17 can be reduced.

[0045] As shown in Fig. 2(b), when the upper split sleeve 107d is separated from the injection sleeve 107, the first split sleeve 107a and the lower split sleeve 107c form a main body 107e having a cylindrical shape with a portion of the upper part cut out. The portion of the main body 107e below the area (hereinafter referred to as "sleeve void 107s") created by the separation of the upper split sleeve 107d is referred to as a lower portion 107f. As shown in Fig. 3(b), the main body 107e can contain the molten metal ML by having its lower end closed by a plunger 109.

[0046] Therefore, for example, molten metal can be poured into the main body portion 107e through the sleeve cavity 107s. From another perspective, after pouring the molten metal, the sleeve cavity 107s can be closed with the upper divided sleeve 107d, thereby sealing the space from the injection sleeve 107 to the mold 101. As a result, for example, it is not necessary to connect the molten metal supply pipe 65 (FIG. 7) to the injection sleeve 107 so that the space from the molten metal supply pipe 65 to the injection sleeve 107 is sealed.

[0047] This reduces the likelihood that the impact of injection will be transmitted to the hot water supply pipe 65, compared to a connected configuration. As a result, for example, a material with low impact resistance, such as ceramic, can be selected for the hot water supply pipe 65, improving design freedom. From another perspective, the injection speed can be increased. Increasing the injection speed improves quality and / or shortens the cycle time.

[0048] The direction of movement of the upper split sleeve 107d relative to the lower split sleeve 107c (main body 107e) is, for example, a lateral direction (for example, horizontal direction, D2 direction) that intersects (for example, is perpendicular to) the mold opening / closing direction (D1 direction). From another perspective, the lateral direction is a direction that intersects (for example, is perpendicular to) the injection direction.

[0049] Because the direction of movement of the upper split sleeve 107d intersects with the mold opening / closing direction, for example, when combining the upper split sleeve 107d with the main body 107e into which molten metal has been poured, the upper split sleeve 107d can be moved between the closed fixed mold 103 and the movable mold 105 (or, from another perspective, the second split sleeve 107b). As a result, for example, mold clamping can be performed immediately after supplying molten metal. Furthermore, during mold clamping, the fixed mold 103 can press the upper split sleeve 107d against the second split sleeve 107b, improving airtightness.

[0050] It is clear that the direction of movement of the upper split sleeve 107d when it separates may be either the -D2 side (illustrated example) or the +D2 side. However, for the sake of convenience, the illustrated example will be used in the description of the embodiment.

[0051] The amount of movement of the upper divided sleeve 107d is arbitrary as long as a space is formed that allows hot water to be supplied to the main body 107e. In the illustrated example, the amount of movement is set so that the entire upper end opening of the lower portion 107f is exposed upward. Furthermore, the amount of movement is set so that the upper divided sleeve 107d does not completely retract from the lower divided sleeve 107c (so that the overlap between the two is maintained).

[0052] The injection sleeve 107 and the divided sleeves (107a to 107d) may have any shape and size.

[0053] For example, the internal shape of the injection sleeve 107 is approximately a right circular cylinder. The external shape of the injection sleeve 107 is approximately a rectangular parallelepiped. The first divided sleeve 107a and the second divided sleeve 107b have a shape obtained by dividing the injection sleeve 107 into two equal parts in the mold opening / closing direction (D1 direction) by a plane parallel to the D2D3 plane.

[0054] Unlike the above description, the first and second split sleeves 107a and 107b do not have to be divided by a plane parallel to the D2D3 plane. For example, the contacting surfaces of the two sleeves may be shaped to engage with each other in the D3 direction and / or the D2 direction. Furthermore, the first and second split sleeves 107a and 107b may be divided not into two equal parts, but at a position offset to one side, or into three or more equal parts.

[0055] Furthermore, for example, the lower divided sleeve 107c and the upper divided sleeve 107d have a shape obtained by dividing the first divided sleeve 107a in the vertical direction (D3 direction) by a plane parallel to the D1D2 plane. The division ratio is arbitrary, and for example, the vertical length of the upper divided sleeve 107d may be less than 1 / 2 or 1 / 3 or less of the vertical length of the injection sleeve 107 (based on the inner side).

[0056] Unlike the above description, the lower split sleeve 107c and the upper split sleeve 107d do not have to be divided by a plane parallel to the D1D2 plane. For example, the abutting surfaces of the two may have rail-like shapes that engage with each other in the D1 and / or D3 directions (guiding each other in the D2 direction). Stoppers that engage with each other in the D2 direction may be provided to define the range of movement of the lower split sleeve 107c and the upper split sleeve 107d in the D2 direction. Although this reduces the rate at which molten metal can be filled into the injection sleeve 107, the vertical length of the upper split sleeve 107d may be at least half the vertical length of the injection sleeve 107.

[0057] In the illustrated example, the upper split sleeve 107d is assumed to move parallel to the D2 direction. The dividing plane between the upper split sleeve 107d and the lower split sleeve 107c is a plane that is roughly parallel to the D1D2 plane. However, it is also possible to divide the dividing plane by a plane that is inclined so that the -D2 side is closer to the -D3 side, and to separate the upper split sleeve 107d by moving both to the -D2 side and the -D3 side.

[0058] The injection sleeve 107 is essentially made of, for example, metal. Each split sleeve may be integrally formed or may be formed by combining two or more members. For example, the engaging and / or guiding shape described above may be formed by fixing another member to a member constituting the main part of the split sleeve.

[0059] 4(a) and 4(b) are views of the fixed mold 103 as viewed from the movable mold 105 side. In these figures, for convenience, the parting surfaces (i.e., surfaces that are not cross-sectional surfaces) of the fixed mold 103 that come into contact with the movable mold 105 are hatched. FIG. 4(a) corresponds to FIG. 2(a) or FIG. 2(b). FIG. 4(b) corresponds to FIG. 2(c).

[0060] The mold 101 may be modified as appropriate from a conventional mold 101 so as to enable the above-described operations related to the injection sleeve 107. For example, as shown in FIGS. 3( a) to 3(c) and 4(a), the fixed mold 103 has a pouring cavity 103a for pouring molten metal into the main body 107e. Also, as shown in FIG. 4(b), the fixed mold 103 has a separation cavity 103b for accommodating the upper split sleeve 107d separated from the lower split sleeve 107c, and a connection cavity 103c that contributes to connecting the upper split sleeve 107d to the sleeve drive unit 19. Parts of the separation cavity 103b and the connection cavity 103c may be formed in the movable mold 105.

[0061] The shape and dimensions of the pouring cavity 103a are arbitrary as long as they do not lead to the upper end opening of the combined injection sleeve 107. In the illustrated example, the pouring cavity 103a is a linear through-hole extending in the direction in which the gutter 111 extends. This allows the gutter 111 to move through the pouring cavity 103a in the extension direction. In this case, the cross-sectional shape of the through-hole is, for example, approximately the same as the cross-sectional shape of the gutter 111 (described below). The cross-sectional dimensions of the through-hole are, for example, larger than the cross-sectional dimensions of the gutter 111 so that the gutter 111 and the fixed mold 103 are not in contact with each other. This reduces the likelihood that the impact caused by injection will be transmitted to the gutter 111.

[0062] However, unlike the illustrated example, the pouring cavity 103a may be indirectly or directly in contact with the gutter 111 via an appropriate buffer material. Furthermore, for example, the pouring cavity 103a may have a lower surface parallel to the D1 direction, a slit-like shape extending toward the bottom of the fixed mold 103 (a notch-like shape formed by cutting out the bottom of the fixed mold 103), or a width in the D2 direction greater than the diameter of the injection sleeve 107. In such cases, the gutter 111 may (or may not) move parallel to the D1 direction or rotate around a rotation axis parallel to the D2 direction (or around another rotation axis). In an aspect different from the embodiment, the pouring cavity 103a may be sized to allow at least a portion of a ladle to be inserted and removed in place of the gutter 111.

[0063] The shape and dimensions of the separation cavity 103b are arbitrary. In the illustrated example, the separation cavity 103b has a shape and dimensions that allow the upper split sleeve 107d separated from the main body 107e to generally fit therein. Furthermore, the combination cavity 103d (FIG. 4A) in which the upper split sleeve 107d combined with the main body 107e is located also has a shape and dimensions that allow the upper split sleeve 107d to generally fit therein.

[0064] Therefore, for example, the upper split sleeve 107d basically abuts against the fixed mold 103 on the +D3 side, the -D3 side, and the +D1 side (it slides during movement). Furthermore, in the combined state, the upper split sleeve 107d abuts against the fixed mold 103 on the above three sides and the +D2 side, and in the separated state, it abuts against the fixed mold 103 on the above three sides and the -D2 side. On the -D1 side, the upper split sleeve 107d slides or abuts against the movable mold 105 and / or the second split sleeve 107b.

[0065] However, the separation cavity 103b may be larger than such a shape and dimensions. For example, the separation cavity 103b may extend to the side surface on the -D2 side of the fixed mold 103. From another perspective, the separation cavity 103b and the connection cavity 103c do not need to be clearly distinguishable. Furthermore, in the above case, the upper divided sleeve 107d may protrude from the side surface on the -D2 side of the fixed mold 103 after separation (or always).

[0066] Although not specifically shown, at least one of the upper surface and +D1 side surface of the combining cavity 103d and the upper surface, lower surface, and +D1 side surface of the separation cavity 103b may have a rail-like shape to guide the upper split sleeve 107d. The cross-sectional shape may be a simple convex or concave shape, or may be T-shaped (the same applies to other rail-like shapes). The outer surface of the upper split sleeve 107d may protrude toward the +D1 side more than the outer surface of the lower split sleeve 107c, and the combining cavity 103d may have a lower surface that supports the upper split sleeve 107d. In this case, the lower surface may have a rail-like shape to guide the upper split sleeve 107d.

[0067] Regarding the mold 101, matters not specifically mentioned may be the same as, for example, the conventional configuration. For example, the method of fixing the lower split sleeve 107c to the fixed mold 103 and the method of fixing the second split sleeve 107b to the movable mold 105 may be the same as the conventional fixing methods. Also, for example, the positional relationship in the D1 direction between the dividing surfaces of the first split sleeve 107a and the second split sleeve 107b and the dividing surfaces of the fixed mold 103 and the movable mold 105 may or may not match (as in the illustrated example).

[0068] The sleeve drive unit 19 may have any configuration. For example, the drive system of the sleeve drive unit 19 may be hydraulic (e.g., oil pressure), gas pressure (including systems using air; the same applies below), or electric. More specifically, the sleeve drive unit 19 may be, for example, a hydraulic or gas pressure cylinder, or a linear motor. Furthermore, the sleeve drive unit 19 may include a rotary motor and a mechanism for appropriately converting rotary motion into linear motion.

[0069] The member to which the sleeve drive unit 19 is fixed is arbitrary. Such members include the fixed mold 103, the fixed die plate 15, and / or other fixed members. Furthermore, when the sleeve drive unit 19 is fixed to the fixed mold 103, the fixed portion of the sleeve drive unit 19 may be located partly or entirely inside the fixed mold 103, or may be located entirely outside the fixed mold 103.

[0070] As a more detailed example, the sleeve drive unit 19 may be, for example, an application of a drive unit for a movable core (a so-called extraction device), or may have a configuration completely different from such a configuration. 4(a) and 4(b) show an example of a hydraulic cylinder in which a main body (a cylindrical member) is fixed to the fixed mold 103 and a rod is fixed to the upper split sleeve 107d.

[0071] (1.4. Other Examples of Injection Sleeve) FIGS. 5(a) to 5(c) are diagrams showing an injection sleeve 107A according to another example, and correspond to FIGS. 2(a) to 2(c).

[0072] In the injection sleeve 107, the region (sleeve cavity 107s) that is vacant when the upper split sleeve 107d is separated is not blocked by another member. On the other hand, the injection sleeve 107A according to another example has a replacement sleeve 107h that blocks the sleeve cavity 107s.

[0073] The shape and dimensions of the replacement sleeve 107h are, for example, approximately the same as those of the upper divided sleeve 107d, with a passage space 107k formed therein for allowing the molten metal to pass through. By supplying the molten metal to the main body 107e through the passage space 107k, which has an area smaller than that of the sleeve space 107s, the likelihood of the molten metal splashing onto the fixed mold 103 (e.g., the inner surface of the combining space 103d) is reduced.

[0074] The replacement sleeve 107h is fixed to the upper split sleeve 107d and moves together with the upper split sleeve 107d. The two may be integrally formed and fixed to each other, or may be fabricated separately and then fixed. In the latter case, the fixing may be removable, such as with bolts, or may be non-removable, such as with welding.

[0075] The shape and dimensions of the passage space 107k are arbitrary. For example, the passage space 107k is formed by cutting out the upper end of the replacement sleeve 107h. The horizontal inner diameter of the passage space 107k is smaller than the diameter of the injection sleeve 107A. More specific shape and dimensions are, for example, such that the gutter 111 contacts the passage space 107k from below and on the left and right, and the passage space 107k is slidable directly or indirectly in the direction in which the gutter 111 extends.

[0076] Unlike the illustrated example, the passage space 107k may be, for example, a through-hole or a notch formed by cutting out the lower end of the replacement sleeve 107h. The passage space 107k may have a size such that it does not come into contact with the gutter 111. The horizontal diameter of the passage space 107k may be equal to the inner diameter of the injection sleeve 107A.

[0077] As mentioned above, the shape of the replacement sleeve 107h is based on the shape of the upper split sleeve 107d. Therefore, for example, the replacement sleeve 107h has a semi-cylindrical recess on the side of the second split sleeve 107b. This allows the entire upper end opening of the lower portion 107f to be open upward, facilitating pouring of molten metal. However, such a recess does not have to be formed, or conversely, the recess may be larger than the recess of the upper split sleeve 107d.

[0078] Furthermore, for example, the upper and lower surfaces and the -D1 and +D1 side surfaces of the replacement sleeve 107h are continuous with (flush with) the upper split sleeve 107d, and like the upper split sleeve 107d, can come into contact with (slide in another sense) with other members (the lower split sleeve 107c and the fixed mold 103). Note that, like the upper split sleeve 107d, an appropriate shape such as a rail may be formed.

[0079] Although not particularly shown, the mold 101 may be modified as appropriate to accommodate the provision of the replacement sleeve 107h. Specifically, for example, when the upper divided sleeve 107d is combined with the main body 107e, a void for accommodating the replacement sleeve 107h may be formed in the fixed mold 103. Also, for example, a rail for guiding the replacement sleeve 107h may be provided.

[0080] In the description of the embodiment, the former of the injection sleeves 107 and 107A will be basically taken as an example. Unless a contradiction occurs, the term injection sleeve 107 may be replaced with the term injection sleeve 107A.

[0081] (1.5. Gutter and Gutter Drive Unit) As shown in Figures 1 and 3(a) to 3(c), a gutter 111 is inserted and removed from the area (sleeve void 107s) left vacant when the upper split sleeve 107d is retracted. The molten metal is poured into the main body 107e through the gutter 111, which is inclined relative to the horizontal direction. From another perspective, the molten metal flowing through the molten metal supply pipe 65 is supplied to the gutter 111, rather than directly to the main body 107e.

[0082] Therefore, for example, as shown in Figure 3(b), the position of the gutter 111 during pouring can be made closer to the inside of the main body 107e than to the inner surface on the +D1 side of the combining cavity 103d of the fixed mold 103, thereby reducing the likelihood of the molten metal splashing outside the main body 107e. On the other hand, by retracting the gutter 111 from the combining cavity 103d after pouring, the likelihood of the gutter 111 obstructing the movement of the upper split sleeve 107d can be reduced (see Figure 3(c) for the view after movement).

[0083] From another perspective, the above-mentioned effect can be obtained even if hot water supply pipe 65 is fixed. Just to be clear, unlike the embodiment, a mode in which hot water is directly supplied to main body 107e by hot water supply pipe 65 may be adopted, and in this case, hot water supply pipe 65 may or may not be inserted into and removed from combination space 103d.

[0084] Unlike the embodiment, a mode in which molten metal is poured into the trough 111 by a ladle may be applied to the die casting machine 1. In this case, compared to a mode in which molten metal is poured directly into the main body 107e by a ladle without using the trough 111, for example, there is less need to enlarge the pouring cavity 103a of the fixed mold 103.

[0085] The specific shape, size and arrangement of the gutter 111 are arbitrary.

[0086] For example, the gutter 111 may be cylindrical or semi-cylindrical with an open top. When the gutter 111 is cylindrical, the portion (upper end portion) into which the molten metal is poured from the molten metal supply system 51 may be semi-cylindrical with an open top, or may extend vertically upward while remaining cylindrical. In addition, in the cylindrical or semi-cylindrical gutter 111, the portion into which the molten metal is poured from the molten metal supply system 51 may or may not be formed in a specific shape (for example, a funnel shape). The end of the gutter 111 on the injection sleeve 107 side may or may not be formed in a specific shape.

[0087] Furthermore, for example, the cross-sectional shape of the gutter 111 may be circular (if cylindrical) or semicircular (if semi-cylindrical). The shape and dimensions of the cross-section are constant, for example, over the entire length (or over 80% or more). The width of the outer surface or inner surface of the gutter 111 may be equal to or less than the inner diameter of the injection sleeve 107. In this case, the ratio between the two is arbitrary. Note that, unlike the above description, other shapes may be adopted as the cross-sectional shape, or the shape and dimensions of the cross-section may be changed. There may be a portion with a diameter larger than the inner diameter of the injection sleeve 107.

[0088] Furthermore, for example, the entire gutter 111 (or the majority of 80% or more) may extend linearly. However, it is also acceptable for the entire gutter 111 to be partially or entirely curved. Furthermore, for example, the gutter 111 may extend parallel to the direction D1 in a top view (as in the illustrated example), or may extend at an angle to the direction D1. In the former case, it is easy to shorten the length of the gutter 111. In the latter case, for example, when the gutter 111 is applied to a die-casting machine 1A according to another example described later, it is easy to position the gutter 111 to avoid the injection device 9A.

[0089] The gutter 111 is inclined so that the entire gutter 111 is positioned lower toward the injection sleeve 107. The specific angle of inclination is arbitrary. The lower end of the cylindrical gutter 111 on the injection sleeve 107 side may extend vertically downward. In this case, the inner surface on the +D1 side of the combining cavity 103d may have a cavity that accommodates the lower end of the gutter 111 when it is retracted from the combining cavity 103d.

[0090] Unlike the embodiment, the injection sleeve 107 having the upper divided sleeve 107d can be combined with an embodiment in which the molten metal is transferred to the main body 107e by an electromagnetic pump. In this case, the pipe for transferring the molten metal in place of the trough 111 does not have to be partially or mostly located as low as the injection sleeve 107.

[0091] When the gutter 111 is inserted into the combination cavity 103d (when pouring molten metal) ( FIG. 3( b) ), the position of the end (lower end) of the gutter 111 on the injection sleeve 107 side is arbitrary. For example, as shown in FIG. 3( b), the position of the lower end of the gutter 111 (more specifically, the lower edge of the opening at the lower end) may be located closer to the interior of the combination cavity 103d (toward the −D1 side) than the inner surface of the +D1 side of the combination cavity 103d, or may be located closer to the interior of the main body 107e (toward the −D1 side) than the inner surface of the lower divided sleeve 107c. However, the lower end of the gutter 111 may be located closer to the +D1 side than the above, so that the molten metal flows through part of the −D1 side of the pouring cavity 103a of the fixed mold 103.

[0092] The above description may be applied to the case where the injection sleeve 107A is used. In addition, when the injection sleeve 107A is used, the lower end of the gutter 111 may be located within the passage space 107k of the replacement sleeve 107h, and the molten metal may flow through a portion of the -D1 side of the passage space 107k.

[0093] When the gutter 111 is retracted from the combination cavity 103d (during injection) (FIG. 3(c)), it is clear that the position of the gutter 111 is arbitrary as long as the gutter 111 does not hinder the movement of the upper split sleeve 107d. The lower end of the gutter 111 may be located in the pouring cavity 103a (as shown in the example), or may be pulled out of the pouring cavity 103a. In the former case, for example, the retracted position may be set so that the gutter 111 is out of contact with the upper split sleeve 107d by a predetermined amount and the amount of movement of the gutter 111 is minimized. As already mentioned, the direction of movement of the gutter 111 is arbitrary.

[0094] The gutter drive unit 23 ( FIG. 1 ) may have any configuration. For example, the drive system of the gutter drive unit 23 may be hydraulic (e.g., oil pressure), gas pressure, or electric. More specifically, for example, in a mode in which the gutter 111 moves in parallel, the gutter drive unit 23 may be a hydraulic or gas pressure cylinder, or a linear motor. The gutter drive unit 23 may also include a rotary motor and a mechanism that appropriately converts rotary motion into linear motion.

[0095] The member to which the gutter driver 23 is fixed is arbitrary. For example, the gutter driver 23 may be installed on the floor of a factory or the like. That is, the gutter driver 23 may not be fixed to a member supporting the mold 101 and injection sleeve 107 (e.g., the fixed die plate 15 and the base (reference numeral omitted) supporting the fixed die plate 15). In this case, for example, the likelihood that an impact due to injection or the like will be transmitted to the gutter 111 via the gutter driver 23 is reduced. However, unlike the above description, the gutter driver 23 may be fixed to such a supporting member (e.g., the fixed die plate 15) or the fixed mold 103.

[0096] (1.6. Operation of the Die Casting Machine) FIG. 6 is a flowchart illustrating a molding cycle executed by the molding system MS (die casting machine 1). From another perspective, it is a flowchart illustrating the procedure of the molding process executed by the controller 5. The molding cycle (in other words, the illustrated process) is started in response to an operation on the interface 13, for example.

[0097] In step ST1, the controller 5 controls the mold clamping unit 7 to close the mold. When the mold closing is completed, the first divided sleeve 107a and the lower divided sleeve 107c are combined to form the main body 107e (FIG. 2B).

[0098] In step ST2, the controller 5 controls the hot water supply system 51 to supply hot water. At this time, the upper split sleeve 107d is separated from the main body 107e (FIGS. 2(b) and 3(b)). The molten metal is poured into the main body 107e through the area (sleeve void 107s) created by the separation of the upper split sleeve 107d and the gutter 111 inserted into the sleeve void 107s.

[0099] The separation of the upper divided sleeve 107d and the insertion of the groove 111 may be performed before, during, or after the mold is closed. However, as will be understood from the description below, in the illustrated example, the separation and insertion are performed before the mold is closed.

[0100] In step ST3, the controller 5 controls the sleeve driving unit 19 to retract the gutter 111 from the sleeve void 107s.

[0101] In step ST4, the controller 5 controls the sleeve driver 19 to combine the upper divided sleeve 107d with the main body 107e, thereby forming the injection sleeve 107 (FIG. 2C).

[0102] In step ST5, the controller 5 controls the mold clamping device 7 to perform mold clamping. This reduces the gap between the fixed mold 103 and the movable mold 105, and also reduces the gap between the first divided sleeve 107a and the second divided sleeve 107b. From another perspective, because mold clamping is not performed in step ST4, movement of the upper divided sleeve 107d is facilitated.

[0103] In step ST6, the controller 5 controls the plunger driver 21 to perform injection (FIG. 3C). The molten metal filled in the die 101 then solidifies to form a die-cast product.

[0104] In step ST7, the controller 5 controls the mold clamping device 7 to open the mold. As the mold opens, the first divided sleeve 107a and the second divided sleeve 107b are also separated. Then, the die-cast product is removed.

[0105] In step ST8, the controller 5 determines whether or not a termination condition for terminating the repetition of the molding cycle has been satisfied. The termination condition is, for example, that the number of repetitions of the molding cycle has reached a preset number via the interface 13. If the determination is affirmative, the controller 5 terminates the illustrated process, and if the determination is negative, the controller 5 proceeds to step ST9.

[0106] In step ST9, the controller 5 controls the sleeve driving unit 19 to separate the upper divided sleeve 107d from the lower divided sleeve 107c. Unlike the illustrated example, this separation may be performed simultaneously with mold opening.

[0107] In step ST10, the controller 5 controls the gutter driver 23 to insert the gutter 111 into the sleeve space 107s. Unlike the illustrated example, the insertion may be performed after the start of step ST7 and before step ST8, as long as it is performed after step ST9.

[0108] The above process may be modified as appropriate. For example, in FIG. 6, multiple steps are performed sequentially for convenience, but some of the steps may overlap. For example, the combining operation of the upper divided sleeve 107d in step ST4 may be started during the retreating operation of the gutter 111 in step ST3. Although not specifically shown, the gutter 111 and other components may be cleaned at an appropriate time using an air blower or the like.

[0109] 7 includes a furnace 53 and a water heater 55. Furthermore, the water heater 51 includes a connecting pipe 57 connecting the two together, and a material supply unit 59 that supplies ingots to the furnace 53.

[0110] In the description of the embodiment, for convenience, connecting pipe 57 is described as a separate part from furnace 53 and water heater 55. However, connecting pipe 57 may be regarded as part of furnace 53 or as part of water heater 55. Similarly, material supply unit 59 may be regarded as part of furnace 53.

[0111] The molten metal supply system 51 may be disposed at any position relative to the die casting machine 1. For example, the structure from the furnace 53 to the molten metal supply pipe 65 may be located on the +D1 side of the fixed die plate 15 and at the center of the fixed die plate 15 in the D2 direction. The cross section of the structure from the furnace 53 to the molten metal supply pipe 65 shown in FIG. 7 may be a cross section parallel to the D1 direction.

[0112] Furthermore, for example, when the molten metal supply system 51 is applied to a die-casting machine 1A (FIG. 14) according to another example described later, the structure from the furnace 53 to the molten metal supply pipe 65 may be arranged on the +D1 side of the fixed die plate 15 so as to avoid the injection device 9A. The cross section of the structure from the furnace 53 to the molten metal supply pipe 65 shown in FIG. 7 may be a cross section inclined in the D1 direction.

[0113] (2.2. Meltwater Supply Apparatus) (2.2.1. Meltwater Supply Apparatus in General) As already described, meltwater supply apparatus 55 (FIG. 7) has container 61 and valve element 63 that controls the flow of molten metal. Furthermore, meltwater supply apparatus 55 has, for example, valve drive unit 67 that drives valve element 63, meltwater level sensor 69 that detects the melt level in measuring chamber R1, and gas pressure circuit 71 that supplies inert gas (e.g., nitrogen or argon) to measuring chamber R1. These components will be described in order below.

[0114] (2.2.2. Container) The specific structure, shape, material, dimensions, etc. of the container 61 (measuring chamber R1) are arbitrary. For example, the container 61 may basically have its interior (measuring chamber R1) sealed (except for openings for the inflow and outflow of the molten metal and inert gas) (in the illustrated example), or it may not be sealed. Furthermore, the container 61 may have a built-in heater (reference numeral omitted) (in the illustrated example), or it may not have a built-in heater. The container 61 may be configured by combining an appropriate number of members of appropriate shapes.

[0115] Although not specifically indicated by a reference numeral in Fig. 7, the container 61 is composed of a container body (reference numeral omitted) with an open top and a lid that covers the top of the container body. The measuring chamber R1 is, for example, in the shape of a straight column with its axis extending vertically. However, for example, part or all of the lower side may be in the shape of a funnel (an inverted cone) (see Fig. 11).

[0116] The measuring chamber R1 is open downward. In the example of Fig. 7, this is opened by a through-hole 63a of a valve body 63 formed by the bottom of the container 61. The container 61 allows the molten metal to flow in from below and out of the container 61 downward.

[0117] (2.2.3. Valve) The valve element 63 shown in FIG. 7 moves together with the container 61. Such a mechanism may be referred to as a valve mechanism 62-1 according to a first aspect. On the other hand, as shown in FIGS. 9(a) to 9(c) described below, the valve element 63A may move relative to the container 61. Such a mechanism may be referred to as a valve mechanism 62-2 according to a second aspect. In the description of the embodiment, the reference numerals of the valve mechanism 62-1 and the valve element 63 are mainly used, but these reference numerals may be substituted for 62-2 and 63A unless a contradiction arises.

[0118] 7, the valve body 63 is formed by the bottom of the container 61. The valve body 63 of this embodiment may be formed integrally with the side surface of the container 61, or may be produced separately from the side surface and fixed to the side surface.

[0119] The melt supply device 55 has an inlet P1 through which the molten metal from the furnace 53 flows into the measuring chamber R1, and an outlet P2 through which the molten metal in the measuring chamber R1 flows out to the injection device 9. In the example of FIG. 7 , the inlet P1 and the outlet P2 are formed in a connecting pipe 57 (which may be considered as part of the melt supply device 55, as described above). The inlet P1 communicates with the furnace 53 via the connecting pipe 57. The outlet P2 communicates with the injection device 9 via a melt supply pipe 65.

[0120] At the inflow position (the position in FIG. 7 ), the valve element 63 communicates the inflow port P1 with the metering chamber R1 and blocks the outflow port P2 from the metering chamber R1. At the outflow position (a position moved to the left from the position in FIG. 7 ), the valve element 63 communicates the metering chamber R1 with the outflow port P2 and blocks the inflow port P1 from the metering chamber R1. At the neutral position between these positions, the valve element 63 blocks the metering chamber R1 from both the inflow port P1 and the outflow port P2.

[0121] More specifically, the inlet P1 and the outlet P2 both open toward the metering chamber R1 from below (an example of a first side in the first direction). The valve element 63 has a plate-like portion (the entire valve element 63 is not shown in the example of FIG. 7 ) facing the up-down direction (an example of the first direction) between the metering chamber R1 and the inlet P1 or outlet P2. The valve element 63 moves between an inlet position and an outlet position by translation in the horizontal direction (an example of a second direction intersecting the first direction).

[0122] At the inflow position, the through-hole 63a of the valve body 63 overlaps with the inlet P1, thereby communicating the metering chamber R1 with the inlet P1. The outlet P2 is, for example, closed on the metering chamber R1 side by the valve body 63. However, unlike the illustrated example, the outlet P2 may be partially or entirely located outside the valve body 63, with the metering chamber R1 side being open to the atmosphere (see FIG. 8(a)).

[0123] At the outflow position, the through hole 63a overlaps with the outlet P2, thereby connecting the measuring chamber R1 and the outlet P2. For example, the inlet P1 is closed on the measuring chamber R1 side by the valve body 63. However, this is not the case in an embodiment where the connecting pipe 57 is not sealed (an embodiment different from the embodiment).

[0124] In the neutral position, the through-hole 63a is located between the inlet P1 and the outlet P2 (not overlapping either of them). The description of the outlet position may be applied to the inlet P1 in this case. The description of the inlet position may be applied to the outlet P2 in this case.

[0125] The structure, shape, dimensions, material, etc. of the valve body 63 are arbitrary. The shape and dimensions, as well as the size and positional relationship of the through-hole 63a, the inlet port P1, and the outlet port P2, are also arbitrary. For example, the valve body 63 (and / or the member that slides against the valve body 63) may have a packing on the sliding surface. The plate-shaped portion of the valve body 63 may have any shape that can be roughly considered to be plate-shaped. A plate-like shape can be defined as, for example, a shape in which the thickness (or, from another perspective, the dimension in the direction perpendicular to the movement direction) is greater than the dimension in any other direction. The surface of the plate may have irregularities.

[0126] The valve mechanism according to the first embodiment may have various configurations different from those described above. For example, the facing direction of the valve body 63 (plate-shaped portion) may be horizontal. The molten metal may flow in and out of the lower part of the side surface of the measuring chamber R1. Furthermore, for example, the valve body 63 may have two through holes (flow paths from another perspective). At the inflow position, one through hole may overlap the inlet port P1, and the other through hole may not overlap the outlet port P2. At the outflow position, one through hole may not overlap the inlet port P1, and the other through hole may overlap the outlet port P2.

[0127] A valve mechanism different from that described above may be employed. For example, the valve element may be cylindrical rather than plate-shaped, and may move between the inlet and outlet positions by rotation about an axis or translation in the axial direction. In this embodiment, the inlet P1 and the outlet P2 may be oriented in different directions.

[0128] (2.2.3.2. Valve body according to another example) Figures 8(a) to 8(c) are cross-sectional views showing a valve body 63A according to another example in the valve mechanism of the first aspect. However, the valve body 63A is not another example of the valve body 63, but can also be regarded as a specific example of the valve body 63. Figure 8(a) shows the valve body 63A in the inflow position. Figure 8(b) shows the valve body 63A in the outflow position. Figure 8(c) shows the valve body 63A in the neutral position.

[0129] In this example, the valve body 63A is configured as a plate-like member separate from the side surface (cylindrical body) of the container 61. However, since the container 61 may be configured by combining two or more members, the valve body 63A may be regarded as part of the container 61, as in Fig. 7. The valve body 63A is configured to be wider on the right side of the figure (in the direction from the outlet P2 to the inlet P1) than the side surface of the container 61.

[0130] 8(a) to 8(c) also show examples of inlet P1 and outlet P2 that are different from those shown in FIG. 7. Specifically, inlet P1 and outlet P2 are provided in plate-shaped lower base 73 rather than in connecting pipe 57. Lower base 73 is interposed between valve body 63A and connecting pipe 57 so as to overlap the plate-shaped portion of valve body 63A (the entire valve body 63A in the illustrated example, and therefore the reference number is omitted) from below (from the outside, from another perspective). Accordingly, hot water supply pipe 65 is connected to lower base 73 rather than to connecting pipe 57.

[0131] (2.2.3.3. Valve mechanism according to second embodiment) Figures 9(a) to 9(c) are cross-sectional views showing the valve mechanism according to the second embodiment. The states of Figures 9(a) to 9(c) correspond to Figures 8(a) to 8(c).

[0132] In this example, the valve body 63A is not fixed to the container 61. Furthermore, a plate-shaped upper base 75 is fixed from below to the side portion (cylindrical body) of the container 61. However, the upper base 75 may be regarded as part of the container 61 rather than as a separate member from the container 61. The upper base 75 has an opening 75a that penetrates in the thickness direction. The valve body 63A slides between the lower base 73 and the upper base 75. In other words, the container 61 does not move.

[0133] The valve body 63A moves to the inlet position, the outlet position, and the neutral position, similar to the first embodiment. In each position, the positional relationship of the through-hole 63a of the valve body 63A with respect to the inlet P1 and the outlet P2 is the same. Furthermore, in all three positions, the through-hole 63a overlaps with the opening 75a. This allows the inflow and outflow of molten metal, similar to the first embodiment.

[0134] The structure, shape, dimensions, material, etc. of the upper base 75, which is not included in the first embodiment, are arbitrary. For example, the diameter of the opening 75a may be smaller than (as in the illustrated example), the same as, or larger than the inner diameter of the side surface of the container 61 (but smaller than the outer diameter of the side surface of the container 61). The upper base 75 does not necessarily have to be provided.

[0135] (2.2.4. Valve Drive Unit) (2.2.4.1. Valve Drive Unit in General) The valve drive unit 67 ( FIG. 7 ) may have any configuration. For example, the valve drive unit 67 may be hydraulic (e.g., oil pressure), gas pressure (including those using air), or electric. More specifically, the valve drive unit 67 may be a hydraulic or gas pressure cylinder, or a linear motor. The valve drive unit 67 may also include a rotary motor and a conversion mechanism that appropriately converts rotary motion into linear motion. Examples of conversion mechanisms include a screw mechanism, a link mechanism, and a rack-and-pinion mechanism.

[0136] 7 illustrates a hydraulic or gas pressure cylinder as the valve drive unit 67. In this example, the cylinder body (cylindrical member) is fixed directly or indirectly to the connecting pipe 57 (from another perspective, the inlet port P1 and the outlet port P2), and the rod is fixed directly or indirectly to the valve body 63.

[0137] Although not particularly shown, the position of the valve element 63 may be detected by an appropriate sensor. The sensor may be, for example, a switch (e.g., a limit switch) that detects that the valve element 63 has reached the inflow position or the outflow position (or the neutral position as necessary), or may be a sensor (e.g., an encoder) that can continuously detect the position of the valve element 63. Furthermore, the sensor may be, for example, a sensor that directly detects the position of the valve element 63, or a sensor that detects the position of a movable part of the valve drive unit 67.

[0138] (2.2.4.2. Example using double cylinders) Figure 10 is a perspective view showing an example in which a double cylinder, which will be described later, is used for the valve driver 67. Figure 11 is a cross-sectional view taken along line XI-XI in Figure 10. For convenience, the valve driver 67 in this example may be referred to as valve driver 67A. As indicated by the reference numerals in Figure 11, the valve configurations shown in Figures 8(a) to 8(c) are used as examples.

[0139] The valve drive unit 67A has a double cylinder 77. The double cylinder 77 has a first cylinder 78A and a second cylinder 78B fixed to each other in series. Each cylinder (78A and 78B) has a cylinder member 78a, a piston 78b that slides within the cylinder member 78a, and a rod 78c that is fixed to the piston 78b and extends from the cylinder member 78a. The first cylinder 78A and the second cylinder 78B are fixed to each other at the head side of the cylinder member 78a (the side opposite the rod 78c).

[0140] The rod 78c of the first cylinder 78A is fixed to the lower base 73 (from another perspective, the inlet port P1 and the outlet port P2). More specifically, in the illustrated example, the rod 78c of the first cylinder 78A is fixed to the lower base 73 via the following members: A horizontal first plate 79 including the lower base 73; Two vertical second plates 81 erected on the first plate 79, one of which is on the right side in the figure; A pair of first rods 83 extending from the second plate 81 on the right side in the figure; and a plate-shaped connecting portion 85 fixed to the tips of the pair of first rods 83.

[0141] The rod 78c of the second cylinder 78B is fixed to the valve body 63A. More specifically, in the illustrated example, the rod 78c of the second cylinder 78B is fixed to the right-hand third plate 87 of the two perpendicular third plates 87 fixed to the valve body 63A. The rod 78c of the first cylinder 78A passes through the second plate 81 on the right side of the figure.

[0142] The pair of first rods 83 may also contribute to guiding the cylinder members of the double cylinder 77. The illustrated example also illustrates a mechanism for guiding the container 61. Specifically, the above-mentioned second plates 81 are provided as a pair with the container 61 in between, and a second rod 89 is suspended between them. In addition, a pair of third plates 87 are provided with the container 61 in between, and the second rod 89 is inserted through and guided by the second rod 89.

[0143] 8(a) to 8(c) show examples of the operation of the double cylinder 77. For convenience, the coupling part 85 is shown fixed to the connecting pipe 57. However, the coupling part 85 may actually be fixed to the connecting pipe 57 as shown in the drawings.

[0144] 8A, at the inflow position, the rod 78c of each of the first cylinder 78A and the second cylinder 78B is fully inserted into the cylinder member 78a. In other words, the piston 78b is positioned at the drive limit (hereinafter referred to as the "retract limit") on the head side (opposite the rod 78c).

[0145] 8(b), in the outflow position, the rods 78c of both the first cylinder 78A and the second cylinder 78B are fully extended from the cylinder members 78a. In other words, the pistons 78b are positioned at the drive limit (hereinafter referred to as the "forward limit") on the rod 78c side.

[0146] As shown in Figure 8 (c), in the neutral position, the piston 78b in one of the first cylinder 78A and the second cylinder 78B (the former in the illustrated example) is positioned at its backward limit, and the piston 78b in the other cylinder is positioned at its forward limit.

[0147] In this way, by using the double cylinder 77, three positions, i.e., the inflow position, outflow position, and neutral position, can be realized by positioning the pistons 78b of the first cylinder 78A and the second cylinder 78B at their forward or backward limits. In other words, three positions can be realized by a full stroke.

[0148] Although not shown, each cylinder may be provided with a limit switch that detects when the piston 78 b reaches its forward limit and a limit switch that detects when the piston 78 b reaches its backward limit. The controller 5 may detect that the valve body 63A has reached either position based on signals from the limit switches.

[0149] The first cylinder 78A and the second cylinder 78B may be manufactured, for example, with the expectation that they will be used alone, or may be manufactured from the beginning with the expectation that they will form the double cylinder 77. Furthermore, the two may be fixed together by connecting head-side members that are manufactured separately, or by integrally configuring the head-side portions of both.

[0150] The first cylinder 78A and the second cylinder 78B may have the same or different configurations. For example, the strokes of the first and second cylinders 78A and 78B may be the same (the neutral position may be midway between the inflow and outflow positions) or may be different. The cross-sectional areas of the pistons 78b may also be the same or different.

[0151] The operations illustrated in Figures 8(a) to 8(c) can be realized as long as the first cylinder 78A and the second cylinder 78B are fixed in series. "In series" here means that driving force is applied in series, not that they are coaxially arranged. Furthermore, instead of fixing the cylinder members 78a to each other, the rods 78c may be fixed to each other (the cylinder members 78a may be fixed to the valve body 63A and the lower base 73), or the rods 78c and the cylinder members 78a may be fixed to each other. Furthermore, the two cylinders fixed in series may be configured as multi-stage (telescopic) cylinders.

[0152] Unlike the illustrated example, the double cylinder 77 may be positioned to the left of the valve body 63 in the drawing so that it is fully extended at the inflow position and fully contracted at the outflow position. As can be understood from the explanation in the previous paragraph, it is also possible to determine whether the piston 78b in each cylinder is positioned at the forward limit or the backward limit in the fully extended (or fully contracted) state.

[0153] (2.2.5. Mold Level Sensor) (2.2.5.1. Mold Level Sensors in General) The amount of molten metal in the measuring chamber R1 can be determined, for example, by detecting the molten metal level using the mold level sensor 69 (FIG. 7). The controller 5 can detect, for example, based on a signal from the mold level sensor 69, that the amount of molten metal flowing into the measuring chamber R1 from the inlet P1 has reached the amount for one shot. Then, based on this detection, the controller 5 controls the valve drive unit 67 to switch the valve element 63 from the inlet position to the outlet position.

[0154] The molten metal level sensor 69 may have any configuration. Although not specifically shown, the following are some examples: A detection rod having a pair of electrodes extending in the vertical direction, which are energized when the molten metal level reaches the bottom, thereby detecting the molten metal level; A laser displacement sensor that irradiates a laser beam toward the molten metal surface and receives the reflected light to measure the distance to the molten metal level; An ultrasonic sensor that irradiates an ultrasonic wave toward the molten metal surface and receives the reflected wave to measure the distance to the molten metal level; A linear encoder that detects the upper and lower positions of a float floating in the molten metal; A sensor that detects the molten metal level based on changes in capacitance or inductance according to its position relative to the molten metal. Note that Figure 7 shows an example of a detection rod.

[0155] As can be seen from the above example, the molten metal level sensor 69 may be a switch that detects when the molten metal level has reached a predetermined height, or may be a sensor that can continuously detect various levels of the molten metal level. The molten metal level sensor 69 may be either a contact type or a non-contact type. A non-contact type sensor may be located inside or outside the container 61. In the latter case, the non-contact type sensor may be capable of detecting the molten metal through the lid of the container 61. An example of such a sensor is an ultrasonic sensor. Furthermore, as will be described later, a laser displacement sensor may be used by making part of the lid translucent.

[0156] When the molten metal level sensor 69 continuously detects the height of the molten metal level, the controller 5 (or the calculation unit of the molten metal level sensor 69) may average multiple detection values ​​acquired at a predetermined sampling cycle within a predetermined period of time, and determine the amount of molten metal based on this average value (or control the valve driving unit 67). In this case, for example, the effect of waves on the molten metal surface on the accuracy of determining the amount of molten metal can be reduced.

[0157] The amount of molten metal in the measuring chamber R1 can also be detected by a sensor other than the molten metal level sensor. For example, as will be described later, in a mode in which the molten metal level in the measuring chamber R1 is raised by reducing the pressure in the measuring chamber R1, the amount of molten metal in the measuring chamber R1 (the height of the molten metal level) can be determined by detecting the air pressure in the measuring chamber R1 with a pressure sensor. Also, the total weight of the container 61 and the molten metal in the container 61 may be measured with a load cell, or the flow rate at the inlet P1 may be measured with a flow meter.

[0158] (2.2.5.2. Example using a laser displacement sensor) Fig. 12 is a cross-sectional view showing an example in which a laser displacement sensor is used as the molten metal level sensor 69. For convenience, the molten metal level sensor 69 using a laser displacement sensor will be referred to as molten metal level sensor 69A. Fig. 10, which was referred to in the explanation of the valve drive unit 67, also shows the molten metal level sensor 69A.

[0159] The molten metal level sensor 69A is located above and outside the container 61. A light-transmitting section 61c that transmits light is provided at the top of the container 61. The molten metal level sensor 69A irradiates the molten metal ML with laser light through the light-transmitting section 61c, receives light reflected from the molten metal surface, and detects the distance to the molten metal surface (and therefore the height of the molten metal surface). In this way, the amount of molten metal for one shot is measured.

[0160] The light transmitted through the light-transmitting portion 61c is, for example, visible light (e.g., wavelength of 360 nm or more and 830 nm or less). The material of the light-transmitting portion 61c is, for example, heat-resistant glass, more specifically, quartz glass or borosilicate glass. Note that the portions of the container 61 other than the light-transmitting portion 61c are made of, for example, metal and / or ceramic and do not transmit light.

[0161] In the example of Fig. 12, the molten metal level sensor 69A is housed in a housing 91. The housing 91 helps protect the molten metal level sensor 69A from heat and the like. The housing 91 has a light-transmitting portion 91a at its bottom. The description of the material of the light-transmitting portion 61c may be applied to the material of the light-transmitting portion 91a. The material of the portions of the housing 91 other than the light-transmitting portion 91a is made of, for example, metal and / or ceramic.

[0162] 12, in addition to the molten metal level sensor 69A, a detection rod (hereinafter referred to as the molten metal level sensor 69B) having a pair of electrodes is also provided. In this example, the molten metal level sensor 69B is used not to detect the amount of molten metal for one shot, but to detect that the molten metal level has reached a predetermined height when some kind of malfunction occurs in the molten metal level sensor 69A.

[0163] Therefore, the molten metal level detected by the molten metal level sensor 69B is set higher than the molten metal level corresponding to the amount of molten metal for one shot. This level may be constant regardless of changes in the amount of molten metal for one shot that occur, for example, when the mold 101 is replaced, or may be set according to changes in the amount of molten metal for one shot. The molten metal level detected by the molten metal level sensor 69B (in other words, a contact sensor) is higher than at least a part of the range of molten metal level that can be detected by the molten metal level sensor 69A (in other words, a non-contact sensor).

[0164] (2.2.6. Gas Pressure Circuit) (2.2.6.1. Gas Pressure Circuit in General) The gas pressure circuit 71 shown in Fig. 7 supplies inert gas to the measuring chamber R1. In the illustrated example, the gas pressure circuit 71 supplies inert gas to the measuring chamber R1 via a gas port 61d that connects the measuring chamber R1 with the outside of the container 61. The position of the gas port 61d may be any position above the assumed height of the molten metal surface in the measuring chamber R1.

[0165] The gas pressure circuit 71 may have various configurations as long as it is capable of supplying the inert gas to the measuring chamber R1. For example, the gas pressure circuit 71 may or may not be capable of controlling the pressure in the measuring chamber R1. Furthermore, the gas pressure circuit 71 may or may not be capable of supplying the inert gas to the furnace 53. The specific configuration for achieving the above-described operation is also arbitrary. The operation of the gas pressure circuit 71 is controlled by, for example, the controller 5.

[0166] 7, the gas pressure circuit 71 has a configuration shown in the lower part of the figure (a configuration including a tank 93) for supplying the inert gas to the measuring chamber R1, and a configuration shown in the upper part of the figure (a configuration including a gas cylinder 95) for sucking the inert gas from the measuring chamber R1. The gas pressure circuit 71 also has an exhaust flow path 97 that supplies the inert gas sucked from the measuring chamber R1 to the furnace 53. Specific configurations of these components are, for example, as follows:

[0167] (2.2.6.2. Configuration Related to Supply of Inert Gas) The gas pressure circuit 71 has a tank 93 that stores inert gas to supply the inert gas to the metering chamber R1. The tank 93 is connected to the metering chamber R1 (gas port 61d). The tank 93 is also used to increase the pressure in the metering chamber R1 by its pressure. By increasing the pressure in the metering chamber R1, for example, when supplying the molten metal from the metering chamber R1 to the injection sleeve 107, the molten metal can be quickly discharged from the metering chamber R1.

[0168] The tank 93 is a sealed container made of metal or the like. The tank 93 is filled with an inert gas at a pressure higher than atmospheric pressure. The pressure of the tank 93 decreases as the inert gas is supplied to the measuring chamber R1. The tank 93 is then replaced with a new tank 93 at an appropriate time. The pressure of the tank 93 is arbitrary. It is also possible to fill the tank 93 with an inert gas using an appropriate device without replacing it.

[0169] Valves for controlling the flow of gas may be provided as appropriate in the flow path (reference numerals omitted) connecting the tank 93 and the measuring chamber R1. In the illustrated example, the following valves are exemplified: a supply valve 151 controlled by the controller 5 to allow or prohibit flow from the tank 93 to the measuring chamber R1; a regulation valve 153 that adjusts the pressure of the gas supplied from the tank 93 to the measuring chamber R1 (to a predetermined pressure, for example); and a check valve 155 that prevents backflow into the tank 93. The specific configurations of these valves are also arbitrary.

[0170] (2.2.6.3. Configuration Related to Suction of Inert Gas) The gas pressure circuit 71 has a gas cylinder 95 for suctioning inert gas from the measuring chamber R1. The gas cylinder 95 has a cylinder member 95a and a ram 95b that is movable axially within the cylinder member 95a. The cylinder member 95a has a space in which inert gas is stored. The volume of this space changes with the movement of the ram 95b. This allows the inert gas to be sucked in or discharged.

[0171] Unlike the illustrated example, the gas cylinder 95 may have a piston that slides within the cylinder member 95a. In other words, a piston may be provided that divides the interior of the cylinder member 95a into two cylinder chambers. In this case, only one of the two cylinder chambers may be used for suction and discharge of the inert gas, or both of the two cylinder chambers may be used for suction and discharge of the inert gas. In the former case, the other of the two cylinder chambers is, for example, open to the atmosphere. In the latter case, when suction is performed in one cylinder chamber, discharge is performed in the other cylinder chamber. Note that in the configuration using the ram 95b and the configuration using only the cylinder chamber on the head side of the piston, fewer seals are required to reduce inert gas leakage than in the configuration using two cylinder chambers.

[0172] The drive mechanism for driving the gas cylinder 95 may have any configuration. For example, the drive mechanism may drive either the cylinder member 95a or the ram 95b (or piston) (the latter in the illustrated example). The drive mechanism may be electric or hydraulic. In the former case, a rotary motor or a linear motor may be used. In the example of FIG. 7 , a rotary electric motor 157, a pulley and belt mechanism 159 that transmits the rotation of the electric motor 157, and a screw mechanism 161 that converts the rotation of the pulley and belt mechanism 159 into linear motion are provided.

[0173] For example, when the volume of the cylinder member 95a expands, the gas pressure circuit 71 allows flow from the metering chamber R1 to the cylinder member 95a and prohibits flow from the exhaust flow path 97 to the cylinder member 95a. Furthermore, for example, when the volume of the cylinder member 95a decreases, the gas pressure circuit 71 prohibits flow from the cylinder member 95a to the metering chamber R1 and allows flow from the cylinder member 95a to the exhaust flow path 97. This allows the inert gas to be sucked from the metering chamber R1 into the gas cylinder 95 and sent from the gas cylinder 95 to the exhaust flow path 97. Unlike the illustrated example, the gas cylinder 95 can also be used to supply the inert gas to the metering chamber R1.

[0174] The specific configuration of the flow paths and valves for achieving the above operation is arbitrary. In the illustrated example, a first check valve 161A, a second check valve 161B, and a control valve 163 are provided. The first check valve 161A allows flow from the metering chamber R1 to the cylinder member 95a and prohibits flow in the opposite direction. The second check valve 161B allows flow from the cylinder member 95a to the exhaust flow path 97 and prohibits flow in the opposite direction. The control valve 163 is controlled by the controller 5 and allows and prohibits flow between the cylinder member 95a and the exhaust flow path 97. For example, the control valve 163 is closed when inert gas is sucked from the metering chamber R1 and is opened when inert gas is delivered to the exhaust flow path 97. Note that in the illustrated example, the control valve 163 can be omitted.

[0175] 7, the flow path extending from the tank 93 to supply the inert gas to the measuring chamber R1 and the flow path extending from the cylinder member 95a to suck the inert gas from the measuring chamber R1 share a portion on the measuring chamber R1 side and the gas port 61d. However, the two may be connected separately to the measuring chamber R1.

[0176] (2.2.6.4. Other Configurations of the Gas Pressure Circuit) The exhaust flow path 97 connects the gas cylinder 95 and the furnace 53. Therefore, the inert gas that flows into the exhaust flow path 97 is supplied to the furnace 53. This reduces, for example, oxidation of the molten metal in the furnace 53. Note that the exhaust flow path 97 does not necessarily have to be provided. For example, the inert gas discharged from the gas cylinder 95 may be released into the atmosphere.

[0177] The exhaust flow path 97 may be connected to any position within the furnace 53 as long as it is connected to a position above the molten metal surface within the furnace 53. In the illustrated example, the exhaust flow path 97 is connected to a temperature control region 53b (described later). However, the exhaust flow path 97 may also be connected to a melting region 53a (described later), or may be branched and connected to both the temperature control region 53b and the melting region 53a.

[0178] The gas pressure circuit 71 may have a pressure sensor 165 that detects the pressure of the inert gas supplied to the metering chamber R1. The position where the pressure is directly detected by the pressure sensor 165 is arbitrary, and may be, for example, a position in the flow path leading from the tank 93 to the metering chamber R1 (as in the illustrated example), a position in the metering chamber R1, or another flow path (for example, a flow path connecting the metering chamber R1 and the gas cylinder 95). The detected value of the pressure sensor 165 is input to, for example, the controller 5 and used to control the gas pressure circuit 71. Note that the pressure sensor 165 does not necessarily have to be provided.

[0179] (2.3. Furnace) The furnace 53 may be a melting and holding furnace that also functions as a melting furnace for melting metal materials (as in the illustrated example), or it may be a holding furnace (in the narrow sense) that does not have a melting function and only has a heat retention function. The melting and holding furnace may melt only the ingot IG, or, although not specifically illustrated, may be configured to be able to melt returned material or other materials (e.g., chips). The ingot IG may be a new ingot and / or a recycled ingot. In the description of the embodiment, the ingot IG will be taken as an example.

[0180] The furnace 53 has a container-shaped furnace body 53c that stores molten metal. The furnace body 53c, although not specifically designated by a reference numeral, may have a container-shaped base and a heater that heats the inside of the base. The interior of the furnace body 53c may be divided by a partition 53d into a melting area 53a and a temperature control area 53b. The melting area 53a is used to melt the ingot IG. The temperature control area 53b is connected to a container 61 of the melt supply device 55 and is used to adjust the temperature of the molten metal to a temperature suitable for molding.

[0181] The opening above the furnace body 53c is closed by a lid 53e. The space above the molten metal surface in the temperature control zone 53b may be sealed by the lid 53e, or may not be completely sealed and be kept at atmospheric pressure. In the description of the embodiment, the latter may be taken as an example unless otherwise specified. The lid 53e has an opening above the melting zone 53a for supplying the material before melting into the furnace body 53c. The furnace 53 may or may not be configured to be able to close the opening. The area above the molten metal surface in the melting zone 53a may or may not be connected to the area above the molten metal surface in the temperature control zone 53b.

[0182] (2.4. Other Configurations of the Meltwater Supply System) The configuration of the connecting pipe 57 (its internal flow path; hereinafter, the same applies unless otherwise specified unless a contradiction occurs) connecting the furnace body 53c of the furnace 53 and the container 61 of the meltwater supply device 55 is arbitrary. In the example of FIG. 7 , the connecting pipe 57 is inserted into the molten metal in the furnace body 53c from the molten metal surface. More specifically, the connecting pipe 57 is inserted through the lid 53e and inserted into the molten metal. Unlike the example shown in the figure, the connecting pipe 57 may be inserted through the side of the furnace 53 above the molten metal surface in the furnace 53 and be bent before being inserted into the molten metal. The connecting pipe 57 may also be connected to an opening located on the side of the furnace 53 below the molten metal surface in the furnace 53. The connecting pipe 57 may also have a built-in heater.

[0183] The material supply unit 59 that supplies the pre-melting material to the furnace body 53c may have any configuration. For example, the material supply unit 59 may be configured to immerse the lower portion of a vertically long ingot IG by the required length into the molten metal in the furnace body 53c, or may be configured to feed the required number of ingots IG (which may be as few as one) into the molten metal. The material supply unit 59 may be a robot or a belt conveyor. A robot that removes products from the mold 101 after mold opening may also serve as the material supply unit 59.

[0184] The furnace 53 may be provided with a molten metal level sensor 167 that detects the height of the molten metal level. The description of the molten metal level sensor 69 may be applied to the molten metal level sensor 167, unless a contradiction arises. The controller 5 may control the material supply unit 59 based on the detection value of the molten metal level sensor 167 so that the molten metal level at a predetermined time point (e.g., immediately before supplying molten metal) in each molding cycle becomes a predetermined height. In other words, the controller 5 may control the material supply unit 59 so as to supply one shot of material to the furnace 53 for each shot. In this case, for example, an error of less than 2 / 3, 1 / 2, or 1 / 3 of the amount of molten metal for one shot may exist.

[0185] The control of supplying one shot of material for each shot is not limited to that based on the molten metal level sensor 167. For example, in a configuration in which the required number of ingots IG are charged, an integer multiple (or even 1) of the number of ingots IG may correspond to the amount of molten metal for one shot, and the integer number of ingots IG may be supplied for each molding cycle. Also, in a configuration in which a vertically long ingot IG is gradually immersed in the molten metal, the ingot IG may be immersed a constant length for each molding cycle.

[0186] (2.5. Method of Transferring Molten Metal, etc.) In the example of FIG. 7 , the inlet P1 is located above the molten metal surface in the furnace 53. In this case, any method can be used to transfer the molten metal in the furnace 53 above the molten metal surface in the furnace 53. For example, the pressure in the measuring chamber R1 can be reduced by a gas cylinder 95. Alternatively, for example, although not specifically shown, pressure can be applied to the molten metal surface in the furnace 53 (e.g., in the temperature control region 53b) by an appropriate mechanism. Alternatively, for example, although not specifically shown, an electromagnetic pump can be provided in the connecting pipe 57. Two or more of the above methods can be combined. In the description of the embodiments, unless otherwise specified, the description may be based on an example in which the molten metal is transferred by reducing the pressure in the measuring chamber R1.

[0187] Unlike the example in Figure 7, the inlet P1 may be located, for example, below the molten metal surface in the furnace 53. In this case, the molten metal can be supplied from the furnace 53 to the measuring chamber R1 by its own weight. In this case, unlike the example shown in the figure, the connecting pipe 57 is connected, for example, to an opening located on the side of the furnace 53 below the molten metal surface in the furnace 53. The inlet P1 may be located at the same position as the opening in the vertical direction, or may be located above or below it. Note that even when the inlet P1 is located below the molten metal surface in the furnace 53, the above-mentioned method of reducing the pressure in the measuring chamber R1 or the like may be used.

[0188] As described above, the controller 5 determines the molten metal level (the amount of molten metal in the measuring chamber R1) based on the detection value of the molten metal level sensor 69. However, the controller 5 can also determine the molten metal level in the measuring chamber R1 based on the detection value of the molten metal level sensor 167 instead of the detection value of the molten metal level sensor 69. For example, unlike the example shown in the figure, in a configuration in which the inlet P1 is located below the molten metal level in the furnace 53, the molten metal may be supplied to the measuring chamber R1 until the molten metal level in the measuring chamber R1 reaches the same height as the molten metal level in the furnace 53. In this case, the molten metal level in the measuring chamber R1 can be indirectly detected by the molten metal level sensor 167.

[0189] In the above case, the method of adjusting the molten metal surface level in the furnace 53 so that the amount of molten metal for one shot is supplied to the measuring chamber R1 is not limited to adjusting the amount of material supplied to the furnace 53. For example, the pressure inside the furnace 53 may be adjusted.

[0190] (2.6. Operation of the hot water supply system) Figure 13 is a flowchart showing an example of the procedure for processing related to hot water supply executed by the controller 5. This processing is started, for example, when the molding processing described with reference to Figure 6 is started, and is performed in parallel with the molding processing. Furthermore, in one molding cycle, steps ST21 to ST32 shown in Figure 13 are performed once. In the following description, for convenience, while referring to the reference numeral of the valve body 63, reference may also be made to Figures 8(a) to 8(c) which use the reference numeral of the valve body 63A.

[0191] In step ST21, the controller 5 controls the valve drive unit 67 to move the valve element 63 to the neutral position (FIG. 8(c)). As a result, the measuring chamber R1 is isolated from the inlet port P1 and the outlet port P2, and is therefore sealed (except for the gas port 61d).

[0192] In step ST22, the controller 5 controls the gas pressure circuit 71 so that the pressure in the measuring chamber R1 becomes a predetermined pressure. For example, the controller 5 controls the electric motor 157 that drives the gas cylinder 95 so that the pressure in the measuring chamber R1 is reduced to a predetermined pressure that is lower than atmospheric pressure.

[0193] This allows the molten metal to quickly start flowing into the measuring chamber R1 when, for example, the valve element 63 is later moved to the inflow position (step ST24). The predetermined pressure may be, for example, a pressure at which the molten metal level at the inlet P1 does not move when the valve element 63 is moved to the inflow position, or a pressure lower than this that allows the molten metal to flow into the measuring chamber R1.

[0194] In step ST23, the controller 5 determines whether a condition for starting metering has been met. The condition may be, for example, that the molding cycle has progressed to a predetermined stage (in other words, that the die-casting machine 1 has reached a predetermined state). If the determination is affirmative, the controller 5 proceeds to step ST24, and if the determination is negative, the controller 5 waits (repeating step ST23).

[0195] In step ST24, the controller 5 controls the valve drive unit 67 to move the valve element 63 to the inflow position (FIG. 8(a)). This allows the molten metal in the furnace 53 to flow into the measuring chamber R1 through the valve element 63.

[0196] In step ST25, the controller 5 controls the gas pressure circuit 71 (the electric motor 157 that drives the gas cylinder 95, etc.) to start depressurizing the measuring chamber R1 by suctioning the inert gas in the measuring chamber R1. As a result, the molten metal flows into the measuring chamber R1, and the molten metal surface rises.

[0197] In step ST26, the controller 5 determines whether or not the molten metal level in the measuring chamber R1 has reached a predetermined target height based on a signal from the molten metal level sensor 69. If the determination is affirmative, the controller 5 proceeds to step ST27, and if the determination is negative, the controller 5 waits (continuing to reduce the pressure in the measuring chamber R1).

[0198] In step ST27, the controller 5 controls the gas pressure circuit 71 to stop the depressurization. By stopping the depressurization, the molten metal surface in the measuring chamber R1 is maintained at the target height set in step ST26. In other words, the metering of one shot of molten metal is completed. Note that in addition to or instead of stopping the depressurization, control may be performed to close the inlet port P1 (for example, by moving the valve element 63 to the neutral position).

[0199] In step ST28, the controller 5 determines whether or not a condition for starting the supply of molten metal to the die-casting machine 1 has been met. This condition may be, for example, that the die-casting machine 1 is ready to receive molten metal into the injection sleeve 107, such as when mold closing is completed. If the determination is affirmative, the controller 5 proceeds to step ST29, and if the determination is negative, the controller 5 waits (repeats step ST28).

[0200] In step ST29, the controller 5 controls the valve drive unit 67 to move the valve element 63 to the outflow position (FIG. 8(b)). As a result, the molten metal in the measuring chamber R1 is supplied to the injection sleeve 107 through the outflow port P2. Note that step ST29 and step ST30 described below correspond to step ST3 in FIG. 6.

[0201] In step ST30, the controller 5 controls the gas pressure circuit 71 (supply valve 151, etc.) to increase the pressure in the measuring chamber R1 by supplying inert gas to the measuring chamber R1. This allows the molten metal to be quickly supplied from the measuring chamber R1 to the injection sleeve 107. At this time, the pressure in the measuring chamber R1 may or may not reach a pressure higher than atmospheric pressure.

[0202] In step ST31, the controller 5 determines whether a predetermined termination condition is satisfied. Step ST31 may be the same as step ST8 in Fig. 6 (from another perspective, the termination condition may be the same as that of step ST8). If the determination is affirmative, the controller 5 terminates the processing shown in Fig. 13, and if the determination is negative, the controller 5 proceeds to step ST32.

[0203] In step ST32, the controller 5 controls the material supply unit 59 so that unmelted material (e.g., ingot IG) corresponding to one shot is supplied to the furnace 53. As a result, the height of the molten metal surface in the furnace 53 becomes the same as the height before the molten metal was supplied from the furnace 53 to the measuring chamber R1. Then, the controller 5 proceeds to step ST21.

[0204] The illustrated process may be modified as appropriate. For example, steps ST21 and ST22 may not be performed. Furthermore, in a configuration in which the molten metal level in the furnace 53 does not affect the molten metal level in the measuring chamber R1, the ingot IG may be supplied to the furnace 53 at any time after measuring (for example, before supplying the molten metal).

[0205] (3. Die Casting Machine According to Another Example) FIG. 14 is a side view (partially including a cross-sectional view) showing a die casting machine 1A according to another example.

[0206] The die-casting machine 1A (injection device 9A) is configured for lateral injection. However, the injection direction (the direction in which the injection sleeve 107A extends) is not horizontal, but is inclined relative to the horizontal so that it is tilted upward toward the mold 101. The injection sleeve 107A has a molten metal supply port 107z that opens to the top surface at a position opposite the mold 101. The molten metal supply system 51 is configured, for example, so that the lower part of the molten metal supply pipe 65 is located above the molten metal supply port 107z. Molten metal is poured from the molten metal supply pipe 65 into the injection sleeve 107A through the molten metal supply port 107z.

[0207] In this die-casting machine 1A, the molten metal in the injection sleeve 107A is located on the tip 109a side, reducing the likelihood of gas (e.g., air) being entrained in the injection sleeve 107A during injection. Meanwhile, as described in the overview of the embodiment, the molten metal supply system 51 can supply high-quality molten metal to the injection sleeve 107A at a highly accurate rate. Therefore, even with a molding system of this type, high-quality die-cast products can be produced.

[0208] More specifically, the die casting machine 1A is, for example, of a horizontal clamping / horizontal injection type. The die casting machine 1A also has a base 201 that supports the mold clamping unit 7 and the injection unit 9A. The base 201 is inclined so that it is positioned higher toward the left side of the figure (the mold clamping unit 7 side relative to the injection unit 9A). As a result, the die casting machine 1A is inclined not only in the injection direction but also in the mold opening / closing direction at the same inclination angle as the injection direction.

[0209] The die casting machine 1A may have an elevator device 203 that moves the left portion of the base 201 in the figure up and down, thereby achieving the above-mentioned tilt. The elevator device 203 may be capable of lowering the left portion of the base 201 in the figure until the base 201 is horizontal. In this case, for example, the mold clamping device 7 becomes horizontal, making it easier to replace the mold 101. The specific configuration of the elevator device 203 is arbitrary.

[0210] The injection device 9A may have a mechanism for closing the molten metal inlet 107z after the molten metal is supplied to the injection sleeve 107A. The tilt angle during injection is, for example, less than 45°, and may also be less than 30°, less than 20°, or less than 10°. The tilt angle may also be, for example, 2° or more, 10° or more, 20° or more, or 30° or more. The above examples of upper and lower limits may be combined in any way so long as no contradiction occurs.

[0211] The injection sleeve 107 in the example of Figure 1 and the injection sleeve 107A in the example of Figure 14 have in common the fact that the end opposite the mold 101 is positioned lower than the end on the mold 101 side.

[0212] (4. Summary of the Embodiments) In the following description, for convenience, a symbol of one of various aspects may be selected and used. However, the matters described below also apply to aspects for which no symbol is used, unless a contradiction arises.

[0213] The molding system MS includes a molding machine (die-casting machine 1) that injects molten metal ML from an injection sleeve 107 into a mold (die 101), and a molten metal supply device 55 that supplies molten metal ML to the injection sleeve 107. The end of the injection sleeve 107 opposite the die 101 is positioned lower than the end on the die 101 side. The molten metal supply device 55 has a measuring chamber R1 that accommodates the molten metal ML and a valve element 63 that moves between an inlet position and an outlet position. In the inlet position, the valve element 63 allows flow from the furnace 53 to the measuring chamber R1 and prohibits flow from the measuring chamber R1 to the injection sleeve 107 of the die-casting machine 1. In the outlet position, the valve element 63 prohibits flow from the furnace 53 to the measuring chamber R1 and allows flow from the measuring chamber R1 to the injection sleeve 107.

[0214] Therefore, as described in the overview of the embodiment, a high-quality molten metal can be supplied in a highly accurate amount to the vertical injection sleeve 107 (or the horizontally inclined injection sleeve 107A), which is less susceptible to gas (air) entrainment, resulting in a high-quality die-cast product.

[0215] The injection sleeve may be for vertical injection. The die casting machine 1 may have a sleeve drive unit 19. The sleeve drive unit 19 may move the upper split sleeve 107d of the injection sleeve 107, which is located above the lower portion 107f of the injection sleeve 107, in a horizontal direction (direction D2) different from the mold opening / closing direction. This may allow the upper split sleeve 107d to be combined with and separated from the main body portion 107e including the lower portion 107f of the injection sleeve 107. The melt supply device 55 may pour molten metal into the main body portion 107e through the area (sleeve void 107s) created by the separation of the upper split sleeve 107d.

[0216] In this case, for example, as already mentioned, since the molten metal supply pipe 65 does not need to be connected to the injection sleeve 107, the likelihood of the injection impact being transmitted to the molten metal supply pipe 65 is reduced. Consequently, by increasing the injection speed, quality can be improved and / or cycle time can be shortened. Furthermore, for example, since molten metal can be supplied in a mold closed state, cycle time can be shortened. Furthermore, for example, mold clamping can improve the sealing between the upper split sleeve 107d and the second split sleeve 107b.

[0217] The mold opening and closing direction may be a lateral direction.

[0218] In this case, for example, in an embodiment in which pouring cavity 103a through which gutter 111 is inserted is formed so as to extend in a direction inclined toward the horizontal, even if the angle of inclination of pouring cavity 103a is large, pouring cavity 103a can be formed only in fixed mold 103. In other words, in an embodiment in which the vertical clamping is performed (this embodiment may also be included in the present disclosure), depending on the angle of inclination of pouring cavity 103a, pouring cavity 103a is formed in both fixed mold 103 and movable mold 105, but this configuration is not the case, and the configuration of pouring cavity 103a is simple.

[0219] In a configuration in which the mold opening / closing direction is horizontal, the injection sleeve 107 may be divided in the mold opening / closing direction above the lower portion 107f, thereby having a main body portion 107e and an upper divided sleeve 107d.

[0220] In this case, for example, the upper split sleeve 107d can be separated from the main body 107e when the mold is opened. As a result, for example, in an embodiment in which a portion (biscuit) formed by solidification of molten metal exists within the upper split sleeve 107d, the biscuit can be easily separated from the upper split sleeve 107d. Also, the upper split sleeve 107d can be pressed against the main body 107e when the mold is closed. As a result, for example, the sealing performance of the injection sleeve 107 can be easily improved.

[0221] In an embodiment in which the mold opening / closing direction is the lateral direction, the injection sleeve 107 may be divided in the mold opening / closing direction and have a first divided sleeve 107a and a second divided sleeve 107b that are separated and combined as the mold 101 is opened and closed. The first divided sleeve 107a may be divided into upper and lower parts and have a lower divided sleeve 107c and the above-mentioned upper divided sleeve 107d. The above-mentioned main body 107e may be the second divided sleeve 107b and the lower divided sleeve 107c in a combined state.

[0222] In this case, for example, in an embodiment in which biscuits are present not only within the upper divided sleeve 107d but also below it, the biscuits can be easily separated from the upper divided sleeve 107d.

[0223] The die casting machine 1 may have a gutter drive unit 23 that moves the gutter 111, which pours the molten metal ML into the lower portion 107f, in and out of the area (sleeve void 107s) that is vacated by the separation of the upper split sleeve 107d.

[0224] In this case, the likelihood of the molten metal splashing outside the main body portion 107 e can be reduced compared to, for example, a mode in which the molten metal is poured into the main body portion 107 e through the sleeve cavity 107 s from outside the sleeve cavity 107 s (this mode may also be included in the technology according to the present disclosure). On the other hand, by retracting the gutter 111 from the sleeve cavity 107 s after pouring, the likelihood that the gutter 111 will obstruct the movement of the upper divided sleeve 107 d can be reduced.

[0225] The area (sleeve void 107s) vacated by the separation of the upper split sleeve 107d may be configured not to be blocked by other members (examples of FIGS. 2(a) to 4(b)).

[0226] In this case, the configuration is simpler than, for example, the embodiment in which the other component (e.g., the replacement sleeve 107h) is provided. Furthermore, the load on the sleeve drive unit 19 is reduced compared to the embodiment in which the sleeve drive unit 19 drives the other component. As a result, for example, costs can be reduced. Furthermore, since the entire sleeve cavity 107s can be used for the passage of molten metal, it is easy to accommodate various molten metal supply methods. For example, unlike the embodiment, it is easy to accommodate a molten metal supply device that pours molten metal into the main body 107e using a ladle.

[0227] The injection sleeve 107 may further include a replacement sleeve 107h that closes the area (sleeve void 107s) that is vacant due to the separation of the upper split sleeve 107d (examples of FIGS. 5(a) to 5(c)). The replacement sleeve 107h may include a void (passage void 107k) that allows the molten metal ML to pass from the outside to the inside.

[0228] In this case, for example, the likelihood of the molten metal scattering outside the main body 107 e can be reduced compared to an embodiment in which the sleeve void 107 s is not blocked. Also, the passage void 107 k can be used to guide the gutter 111, or the passage void 107 k itself can be used as a flow path in which the molten metal comes into contact and flows.

[0229] The molding system MS (injection device 9) may further include a controller 5 that controls the sleeve drive unit 19 so that, after the mold is closed, the molten metal ML is poured into the main body portion 107e from which the upper split sleeve 107d is separated.

[0230] In this case, the time from supplying the molten metal to the start of injection can be shortened compared to a mode in which the mold is closed after supplying the molten metal to the injection sleeve, thereby reducing the possibility of the temperature of the molten metal decreasing and improving the quality of the die-cast product.

[0231] The controller 5 may control the sleeve driving unit 19 so that the upper split sleeve 107d is combined with the main body portion 107e after the molten metal ML is poured into the main body portion 107e and before the mold is closed.

[0232] In this case, for example, since the upper split sleeve 107d is moved before mold clamping, the sliding resistance of the upper split sleeve 107d is small. As a result, for example, the upper split sleeve 107d can be moved quickly and the load on the sleeve drive unit 19 can be reduced. In addition, the strength against sliding of the injection sleeve 107 and / or the mold 101 can be reduced, improving design freedom. On the other hand, for example, the upper split sleeve 107d can be pressed against the main body 107e by mold clamping, improving the sealing performance of the injection sleeve 107.

[0233] The melt supply device 55 may have an inlet P1 and an outlet P2. The inlet P1 may open toward the measuring chamber R1 from a first side in the first direction (the −D3 side in the D3 direction), and may allow the molten metal ML from the furnace 53 to flow into the measuring chamber R1. The outlet P2 may open toward the measuring chamber R1 from the −D3 side, and may allow the molten metal ML in the measuring chamber R1 to flow out to the injection sleeve 107. The valve body 63 may include a plate-shaped portion facing the D3 direction between the measuring chamber R1 and the inlet P1 and outlet P2, and may move between an inlet position and an outlet position by translation in a second direction (the left-right direction in FIG. 7 ) intersecting the D3 direction.

[0234] Another example of a valve configuration is one in which a cylindrical valve element and a cylindrical body housing the valve element slide in the axial direction (this configuration may also be included in the technology of the present disclosure). In this configuration, if the gap between the valve element and the cylindrical body is large (or, from another perspective, the contact pressure is small), the likelihood of molten metal penetrating into the gap increases. Conversely, if the gap is small (or the contact pressure is large), the sliding resistance increases, resulting in, for example, galling. Furthermore, adjustment of the contact pressure (for example, adjustment of the dimensions of the valve element and the cylindrical body) must be performed during the manufacturing process.

[0235] On the other hand, in the case of a valve element 63 including a plate-shaped portion, the contact pressure can be adjusted by a mechanism for attaching the valve element 63 to a member (connecting pipe 57 or lower base 73) having the inlet port P1 and the outlet port P2, and depending on the configuration of the mechanism, it can also be adjusted on-site. From another perspective, the contact pressure can be adjusted regardless of the dimensional accuracy of the valve element 63, etc. Therefore, the possibility of molten metal entering the gap is reduced, and smooth movement of the valve element 63 is facilitated. Furthermore, the configuration is simple. In addition, there is little need for an operation (dithering operation) that vibrates the valve element to prevent the molten metal from sticking.

[0236] Molding system MS (water heater 55) may further include a valve drive unit 67A that translates valve element 63 in a predetermined direction (second direction, horizontal direction). Valve drive unit 67A may include two cylinders (first cylinder 78A and second cylinder 78B) fixed in series to each other in the predetermined direction.

[0237] In this case, for example, as described above, by driving each of the first cylinder 78A and the second cylinder 78B at their full strokes, three positions, i.e., the inflow position, the outflow position, and the neutral position, can be realized. As a result, for example, control such as controlling the position of the piston 78b based on the position of a position sensor that continuously detects the position of the piston 78b is not necessary. In other words, the position of the valve element 63 can be controlled with high precision using a simple control system.

[0238] The molding system MS (water supply device 55) may further have a non-contact sensor (e.g., a water level sensor 69A configured by a laser displacement sensor) that detects the height of the water surface in the measuring chamber R1 from outside the container 61 that constitutes the measuring chamber R1 via the container 61.

[0239] In this case, for example, there is a low probability that the molten metal will adhere to or even accumulate on the molten metal level sensor 69. Therefore, it is possible to reduce the probability that the detection accuracy will decrease due to such adhesion or accumulation.

[0240] The container 61 may have a light-transmitting portion 61c that transmits light. The non-contact sensor (laser displacement sensor) may detect the molten metal surface level based on light that passes from the molten metal surface in the measuring chamber R1 through the light-transmitting portion 61c to the outside of the container 61.

[0241] In this case, the influence of the heat of the molten metal and / or the fluctuation of the gas caused by the heat on the detection accuracy is low compared to an embodiment in which an ultrasonic sensor is used as the non-contact sensor, for example. In other words, high detection accuracy can be expected.

[0242] The molding system MS (water heater 55) may further have a contact sensor (e.g., a water level sensor 69B formed by a detection rod) that detects a water level that is located above at least a portion of the range of water level heights that can be detected by the non-contact sensor.

[0243] In this case, for example, as described above, even if a malfunction occurs in the non-contact sensor, the likelihood of excessive molten metal being supplied to the measuring chamber R1 is reduced. As a result, for example, a non-contact sensor with high detection accuracy but a low track record of use in terms of heat resistance can be selected.

[0244] The molding system MS (water heater 55) may have a gas pressure circuit 71 that supplies an inert gas to the measuring chamber R1.

[0245] In this case, for example, the probability of oxidation of the molten metal can be reduced, thereby improving the quality of the product.

[0246] The gas pressure circuit 71 may lower the pressure in the measuring chamber R1 below atmospheric pressure by sucking in an inert gas when the molten metal flows from the furnace 53 (or from the inlet P1 in another respect) to the measuring chamber R1.

[0247] In this case, for example, the molten metal can be quickly introduced into the measuring chamber R1. Furthermore, the inert gas is used to reduce oxidation of the molten metal and to introduce the molten metal into the measuring chamber R1. This allows for effective use of the inert gas. As a result, the configuration of the molding system MS is simplified.

[0248] When the molten metal flows from the measuring chamber R1 to the die casting machine 1 (from another perspective, the outlet P2), the gas pressure circuit 71 may supply an inert gas to make the pressure in the measuring chamber R1 higher than atmospheric pressure.

[0249] In this case, for example, the molten metal can be quickly supplied to the injection sleeve 107. Furthermore, the inert gas is used to reduce oxidation of the molten metal and to cause the molten metal to flow out of the measuring chamber R1. This allows for effective use of the inert gas. As a result, the configuration of the molding system MS is simplified.

[0250] The gas pressure circuit may include a cylinder member 95 a and a movable member (e.g., a ram 95 b) that moves axially inside the cylinder member 95 a. The space inside the cylinder member 95 a, whose volume changes as the ram 95 b moves, may be connected to the measuring chamber R1.

[0251] In this case, for example, by driving the ram 95b relative to the cylinder member 95a, the inert gas can be sucked from the metering chamber R1 and / or supplied to the metering chamber R1. As a result, it is easier to grasp the relationship between the drive amount and the flow rate compared to, for example, an embodiment in which the inert gas is sucked and / or supplied by a pump (this embodiment is also included in the technology disclosed herein). Furthermore, fine adjustment of the pressure is also easy. Although different from the operation of the embodiment, it is also possible to reduce the required amount of inert gas by supplying the inert gas sucked from the metering chamber R1 to the metering chamber R1.

[0252] The gas pressure circuit 71 may have an exhaust passage 97 that connects the measuring chamber R1 and the inside of the furnace 53 .

[0253] In this case, for example, the inert gas discharged from the measuring chamber R1 can be effectively utilized by supplying it to the furnace 53. Note that, unlike the example in Fig. 7, the exhaust flow path 97 may connect the measuring chamber R1 and the furnace 53 without passing through the gas cylinder 95. In this case, for example, the inert gas discharged from the measuring chamber R1 when the molten metal in the furnace 53 flows into the measuring chamber R1 due to its own weight may be supplied to the furnace 53, or the inert gas may be supplied to the furnace 53 from the tank 93 or the gas cylinder 95 via the measuring chamber R1.

[0254] The molding system MS may further include a material supply unit 59 that supplies one shot of unmelted material to the furnace 53 for each shot.

[0255] In this case, for example, the furnace 53 can be made smaller, thereby reducing the amount of heat dissipation and ultimately the required energy. In a mode in which the molten metal in the furnace 53 is pumped out using a ladle, the top of the furnace 53 is open for the ladle to be inserted and removed. Therefore, the molten metal in the furnace 53 easily dissipates heat upward. Furthermore, the temperature of the molten metal in the furnace 53 is set relatively high, taking into account the cooling of the molten metal while being transported by the ladle. As a result, the temperature difference between the molten metal and the ambient temperature is increased, promoting heat dissipation. To stabilize the temperature of the molten metal regardless of such heat dissipation factors, the furnace 53 is made relatively large. On the other hand, in a mode in which a ladle is not used, as in the embodiment, an increase in the size of the furnace 53 due to such factors can be avoided. Therefore, by combining a mode in which a ladle is not used with a mode in which one shot's worth of unmelted material is charged into the furnace 53 for each shot, the limit for reducing the capacity of the furnace 53 can be lowered. Furthermore, in a mode in which one shot of material is dropped for each shot, the molten metal level in the furnace 53 is raised by an amount corresponding to the drop in the molten metal level, so that the molten metal level in the furnace 53 is maintained at a constant height. As a result, for example, in a mode in which the molten metal level in the measuring chamber R1 is affected by the molten metal level in the furnace 53, it is easy to control the molten metal level in the measuring chamber R1.

[0256] In the above embodiment, the die-casting machine 1 is an example of a molding machine. The mold 101 is an example of a mold. The D3 direction is an example of a first direction. The -D3 side is an example of a first side. The left-right direction (the movement direction of the valve body 63) in Figure 7, etc. is an example of a second direction and a predetermined direction. The valve body 63 is an example of a valve body and an example of a plate-shaped portion that the valve body includes. The molten metal level sensor 69A is an example of a non-contact sensor. The ram 95b is an example of a movable member.

[0257] The present invention is not limited to the above-described exemplary embodiments, and may be implemented in various forms.

[0258] For example, the molding machine is not limited to a die-casting machine, but may be another metal molding machine. The molding machine is not limited to a horizontal clamping type, but may be a vertical clamping type.

[0259] In vertical injection, an injection sleeve having an upper divided sleeve does not have to be used. Also, in an injection sleeve having an upper divided sleeve, the main body does not have to be separable into a second divided sleeve and a lower divided sleeve.

[0260] The measuring chamber does not need to be supplied with an inert gas. For example, the measuring chamber may be open to the atmosphere. In addition, in a mode in which an inert gas is supplied, the pressure may be any pressure, for example, the pressure may be approximately the same as atmospheric pressure throughout the entire molding cycle.

[0261] From this disclosure, inventions that do not require the end of the injection sleeve opposite the mold to be positioned lower than the end of the injection sleeve facing the mold, or inventions that do not require the presence of a valve disc, may be extracted. For example, an invention of a water heater equipped with a non-contact sensor that detects the molten metal level in the measuring chamber from outside the container that forms the measuring chamber may be extracted. Also, for example, an invention of a water heater in which the valve disc is driven by a double cylinder may be extracted.

[0262] 1... die-casting machine (molding machine), 53... furnace, 55... melting device, 63... valve body, 107... injection sleeve, MS... molding system, R1... measuring chamber.

Claims

1. A molding system comprising: a molding machine that injects molten metal from an injection sleeve into a mold; and a water supply device that supplies molten metal to the injection sleeve, wherein the end of the injection sleeve opposite the mold is positioned lower than the end on the mold side, and the water supply device has: a measuring chamber that contains molten metal; and a valve element that moves between an inflow position that allows flow from a furnace to the measuring chamber and prohibits flow from the measuring chamber to the injection sleeve, and an outflow position that prohibits flow from the furnace to the measuring chamber and allows flow from the measuring chamber to the injection sleeve.

2. The molding system described in claim 1, wherein the injection sleeve is for vertical injection, the molding machine has a sleeve drive unit that moves an upper split sleeve of the injection sleeve that is located above the lower portion of the injection sleeve in a horizontal direction different from the mold opening / closing direction, thereby combining and separating the upper split sleeve with a main body portion including the lower portion of the injection sleeve, and the water heater pours molten metal into the main body portion through the area created by the separation of the upper split sleeve.

3. The molding system according to claim 2, wherein the mold opening / closing direction is a horizontal direction, and the injection sleeve is divided in the mold opening / closing direction above the lower portion, thereby having the main body portion and the upper divided sleeve.

4. The molding system described in claim 3, wherein the injection sleeve is divided in the mold opening / closing direction, and has a first divided sleeve and a second divided sleeve that are separated and combined as the mold is opened and closed; the first divided sleeve is divided into upper and lower parts, and has a lower divided sleeve and the upper divided sleeve; and the main body portion is the second divided sleeve and the lower divided sleeve in a combined state.

5. The molding system according to claim 2, wherein the molding machine has a trough drive unit that moves a trough, which pours the molten metal into the lower portion, into and out of the area vacated by the separation of the upper divided sleeve.

6. The molding system according to claim 2, wherein the area vacated by the separation of the upper split sleeve is not blocked by other members.

7. The molding system according to claim 2, wherein the injection sleeve further comprises a replacement sleeve that closes the area vacant by the separation of the upper split sleeve, and the replacement sleeve has a void that allows the molten metal to pass from the outside to the inside.

8. The molding system according to claim 2, further comprising a controller that controls the sleeve drive unit so that the molten metal is poured into the main body portion from which the upper split sleeve is separated after the mold is closed.

9. The molding system according to claim 8, wherein the controller controls the sleeve drive unit so that the upper split sleeve is combined with the main body portion after the molten metal is poured into the main body portion and before the mold is closed.

10. The molding system according to claim 1, wherein the molten metal supply device has an inlet opening that opens toward the measuring chamber from a first side in a first direction and allows molten metal from the furnace to flow into the measuring chamber, and an outlet opening that opens toward the measuring chamber from the first side and allows molten metal in the measuring chamber to flow out to the injection sleeve, and the valve body includes a plate-like portion that faces the first direction between the measuring chamber and the inlet and outlet, and moves between the inlet position and the outlet position by translation in a second direction that intersects the first direction.

11. The molding system according to claim 1, further comprising a valve drive unit that translates the valve element in a predetermined direction, the valve drive unit having two cylinders fixed in series to each other in the predetermined direction.

12. The molding system according to claim 1, further comprising a non-contact sensor that detects the height of the molten metal surface in the measuring chamber from outside the container that constitutes the measuring chamber via the container.

13. The molding system according to claim 1, further comprising a gas pressure circuit for supplying an inert gas to the measuring chamber.

14. The molding system according to claim 13, wherein the gas pressure circuit reduces the pressure in the measuring chamber below atmospheric pressure by sucking in the inert gas when the molten metal flows from the furnace to the measuring chamber.

15. The molding system according to claim 13, wherein the gas pressure circuit supplies the inert gas to make the pressure in the measuring chamber higher than atmospheric pressure when the molten metal flows from the measuring chamber to the molding machine.

16. A molding system according to claim 13, wherein the gas pressure circuit has a cylinder member and a movable member that moves axially inside the cylinder member, and the space inside the cylinder member whose volume changes as the movable member moves is connected to the measuring chamber.

17. The molding system according to claim 13, wherein the gas pressure circuit has an exhaust passage connecting the measuring chamber and the inside of the furnace.

18. The molding system according to claim 1, further comprising a material supply unit that supplies one shot of unmelted material to the furnace for each shot.

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