A method for removing mould material from a flask

Abstract

The disclosure regards a method for removing mould material from a flask for producing or forming a component, wherein the method comprises providing a flask comprising one or more cavities filled with mould material, attaching a vibrator to the flask at a vibrator position, and activating the vibrator for transmitting one or more frequencies for removing the mould material from the flask.

Description

[0001] P7396PC00

[0002] 1

[0003] A Method for Removing Mould Material from a Flask

[0004] Field of Disclosure

[0005] The disclosure relates to a method for removing mould material, like e.g. sand, from a flask used for producing or forming or casting a component.

[0006] Background of the Disclosure

[0007] When manufacturing components using e.g. casting and moulding processes, mould material, such as sand, is used to define the geometry of the component. After the casting or forming process and final solidification of the component, the mould material will have to be removed.

[0008] According to the prior art the mould material is removed by applying unstructured mechanical force. One common way is to move the flask on top of a vibrating table, where a vibration source vibrates the table so that the vibrations are transferred to the flask for removing mould material. However, this process is energy consuming because also the table, which is generally heavy, will be vibrated, and the flask, which is often very heavy, will have to be lifted over to the table.

[0009] In addition, the use of large industrial stationary and mobile equipment for moving the flask with the mould material may pose a safety issue for the workers close to the process, and the flask may become structurally deformed over time due to repeated jumping on the vibrating table. When the flask jumps, vibrational energy transfer is reduced because contact between the flask and the table is lost during the jump.

[0010] Moreover, moving a large flask is time-consuming, and the removal of the mould material by this method is particularly slow when the flask has a complex or intricate shape. It is also time consuming to move a large flask. Finally, the removal of the mould material using this method from the flask is time-consuming, especially if the flask has a complex and intricate shape.

[0011] Summary of the Disclosure

[0012] Considering the prior art described above, it is an object of the present disclosure to provide a method wherewith mould material like e.g. sand can more easily and at a higher speed be removed from a flask. The flask may be the surrounding that together P7396PC00

[0013] 2

[0014] with the mould material form the cavity, where a component is formed by e.g. casting or injection moulding.

[0015] The object can be achieved by a method for removing mould material from a flask, wherein the method comprises providing a flask comprising one or more cavities filled with mould material, attaching a vibrator to the flask at a vibrator position, and activating the vibrator for transmitting one or more frequencies for removing the mould material from the flask. The vibrator will vibrate a system comprising the flask with the mould material or some mould material and the vibrator attached to the flask. Since the vibrator is attached to the flask and the flask is not resting on top of a vibrator table, the flask will not be structurally deformed over time.

[0016] This method offers significant advantages when removing mould material, such as sand, from a flask. The flask, and especially a flask for producing or forming a large component often weighs more than a metric ton and maybe more than 20 metric tons. The vibrator is smaller and can easily be moved to the flask by hand or by a crane. The flask with the mould material may not need to be moved at all, at least not before the mould material is removed.

[0017] Since the vibrator will only vibrate the flask, less energy will be needed compared to the prior art method. There is no risk issue, or the risk issue is much smaller for the workers close to the process, since the vibrator is much smaller than the substituted large mobile- and stationary industrial equipment. The vibrator is also easier to manoeuvre than the flask. Preferably the vibrator is portable, e.g. by one single person. After some experience, the workers will know where the vibrator should be attached to the flask, or which frequency should be used to target the vibrations to remove the mould material as quickly and as efficiently as possible. The process becomes both much quicker and much more efficient compared to traditional methods. The direct application of specific frequencies targets the mould material within the cavities, reducing the need for manual intervention or additional mechanical processes. This not only speeds up the removal process but also minimizes the labour required, with the additional possibility to decrease energy consumption, significantly reducing maintenance efforts of the flask due to less strain on the flask and reducing the overall environmental impact making the method a cost-effective solution. P7396PC00

[0018] 3

[0019] Regarding the energy consumption, current shake-out tables used for removing mould material from flasks using uncontrolled vibrations via large vibration motors, may consume over 20 kW of input power. The relatively small vibrator used for the present disclosure will just consume around 1 kW of power, representing a 1 :20 efficiency ratio. Since the vibrational energy of the present disclosure is focused only on the movement of the flask, instead of creating noise and other emissions as well as moving a vibration table, not only is the energy consumption reduced but the time necessary for removing the mould material is also reduced, may be as much as a third.

[0020] The present method of removing mould material like sand from a flask is much less noisy compared to the conventional method using a table to vibrate the flask for removing mould material.

[0021] With no table on which the flask has to be positioned when the vibrations are applied, there will be less capital expenditure required, as the system size and complexity is significantly reduced.

[0022] Attaching the vibrator to the flask at the vibrator position may comprise fastening the vibrator to the flask using e.g. one or more fastening means, like bolts, screws or clamps. Attaching the vibrator to the flask at the vibrator position also makes the process much more scalable as the disclosure that provides a method that is not bound to stationary and / or mobile, heavy equipment, but can be carried out anywhere, as long as power is available. Up and downscaling is much easier, and the space needed is less, leading to better usage of floor space.

[0023] Moreover, the use of vibrations ensures that even hard-to-reach areas within the flask may be effectively cleared of mould material. In many cases, traditional methods might struggle with removing compacted or tightly bound mould material or sand, especially in complex or narrow cavities.

[0024] The method is also beneficial, since by providing a vibrator, in principle any flask can be cleared from the mould material.

[0025] The frequency provided by the vibrator may be changed. By adjusting the frequency of the vibrator, the process can be customized to suit different types of mould materials or P7396PC00

[0026] 4

[0027] flask- or cavity designs or to remove mould materials in cavities having different shapes and / or sizes. This flexibility enhances its application across various industries and component types, making it a versatile solution for mould material removal.

[0028] Additionally, the increased speed of the process can contribute to overall production efficiency, allowing for a higher throughput of components and reducing downtime between casting cycles.

[0029] In one embodiment, the flask containing the mould material has a mass of at least 500 kg. The method is particularly advantageous for such heavy flasks, since moving the vibrator is considerably easier than moving the flask with the mould material, thereby facilitating removal of the mould material from the flask.

[0030] In one embodiment, the method comprises the step of securing, fastening, or directly attaching the vibrator to the flask at a vibrator position, e.g. such that the vibrator is secured, fastened, and / or directly attached only to the flask. Such a feature can be beneficial, as it enables the secure attachment of the vibrator on the flask, without requiring further elements to perform the method, which would make the process more complicated and less customizable. Advantageously, a user can e.g. screw the vibrator on the flask or clamp the vibrator to the flask. That the vibrator is directly attached to the flask means that the vibrator and the flask are attached in such a way that the vibrator and the flask form one system that will co-vibrate as one unit - i.e. uniformly. That the vibrator is directly attached to the flask means that the vibrator and the flask are attached without springs in between. Any other means of securing or fastening may be used. If the user wants to attach the vibrator on a different location of the flask, the user can simply remove the vibrator and secure or fasten it on a different location of the flask. Such a feature is advantageous because it may become evident during operation of the vibrator that the location of attachment on the flask is not optimal. Therefore, a user may reposition the vibrator to accelerate and optimize the process of removing the mould material from the flask. In addition, securing, fastening or directly attaching the vibrator to the flask enables customization and versatility of the presently disclosed method, as the method does not require the use of additional components in order to perform the removal of the mould material.

[0031] In one embodiment, the vibrator is attached on any accessible surface of the flask, like on top of or on the side of the flask. Different positions of attaching the vibrator can be P7396PC00

[0032] 5

[0033] beneficial, if for example it is found that certain locations on the flask relate to a more efficient process. For instance, depending on the geometry and the characteristics of the flask, as well as the type of mould, by positioning the vibrator on one side of the flask may lead to stronger vibrations compared to positioning on a different location. The vibrator may be repositioned during operation. Since the flask may easily weigh several metric tons and be difficult to move around, the vibrator being attached on any accessible surface of the flask,, like on top of or on the side of the flask, allow the vibrator and the flask to be more easily positioned in relation to each other, so that mould material can more effectively and faster be removed from the flask. Alternatively, the vibrator may or may not be placed underneath the flask.

[0034] In one embodiment, the vibrator has one or more planar sides, like outwardly oriented planar side(s), pointing in different directions, and the vibrator is attached to the flask so that not more than the three sides are touching or being attached to the flask, preferably not more than two sides are touching the flask, or most preferably not more than one side is touching the flask, when the vibrator is activated. The one or more sides or planar sides may be outwardly oriented seen from the centre of or from inside the vibrator. This embodiment may be implemented with a vibrator unit having a frame with one, two, or three outwardly oriented planar faces oriented in different directions. Limiting the number of sides in contact with the flask to not more than three, and preferably not more than two, may help ensure that the vibration energy is transmitted into the flask at discrete points rather than being damped or dissipated over a large surface area. This may be advantageous because concentrated contact points may increase the local acceleration and vibration amplitude, thereby improving the efficiency of energy transfer into the structure of the flask. In one implementation, two opposite sides of the vibrator may be mounted against the flask with elastomeric pads in between, allowing controlled coupling stiffness while reducing high-frequency noise transmission. Alternatively, the vibrator may be mounted with only one or two edges or corners in contact with the flask, for instance through point-like fixtures, to achieve even more localized excitation and to prevent excessive damping by the mounting structure itself. The remaining sides of the vibrator may be exposed to the air or to isolation mounts, reducing unwanted vibration transmission to surrounding equipment. The orientation of the sides pointing in different directions may also be chosen so that the resulting force vectors include both vertical and horizontal components, thereby exciting a broader range of vibration modes within the system of the flask, with the P7396PC00

[0035] 6

[0036] mould material, and the vibrator. With three sides touching or being attached to the flask, the vibrator can be attached to the flask in any corner of the flask. With two sides touching or being attached to the flask, the vibrator can be attached to the flask at any edge of the flask. With one side touching or being attached to the flask, the vibrator can be attached to the flask anywhere on the flask.

[0037] In one embodiment, one, two, three, or more fixation points positioned underneath, and / or on, and / or attached to the flask at specific fixation positions. The fixation points may be part of the flask. These fixation points may secure the flask in place during the vibration process, ensuring stability and allowing the vibrations to be effectively transmitted throughout the system of the flask, with the mould material, and the vibrator. By strategically placing these fixations, the process may enhance the efficiency of mould material removal, as the flask may remain securely positioned, minimising unwanted movement and ensuring that the vibrations are directed where they are most effective. The fixation(s) may be screwed or in any other way attached to the flask and to the floor underneath the flask, so that the flask is well secured in a stable position. The fixation(s) may be screwed or clamped or in any other way attached to the flask and to a wall or a ceiling or a heavy structure next to or above the flask, so that the flask is well secured in a stable position. Preferably, the fixation(s) is / are made of a material, like e.g. rubber, polyurethane, viscoelastic polymers (sorbothane), or polyvinyl chloride (PVC), that dampens vibrations, so that a system comprising the flask with the mould material or some mould material and the vibrator attached to the flask is isolated from the surrounding environment. The system may be understood as comprising everything that is vibrated by the vibrator and / or everything that influences the resonance frequency of the system. That the vibrations are damped by the fixation(s) prevents the vibrations from spreading to the floor, walls, or ceiling, reducing energy consumption and improving the working environment for the workers.

[0038] In one embodiment, at least one, two, three, or more of the fixation points may be isolator(s). These isolator(s) may help to minimise the transfer of vibrations beyond the intended areas of the flask, enhancing control over the vibration process. By isolating certain areas, the vibrations may be more precisely directed at the targeted area for the removal of mould materials, improving the efficiency and effectiveness of the removal process. The isolators may also prevent potential impact on surrounding equipment and / or structures by containing the vibrational transmission within the system itself. The P7396PC00

[0039] 7

[0040] isolator(s) may be block(s), which may be suitable underneath the flask, where the flask is resting on the fixation(s). The isolators may be chains or straps so that one or more sides of the flask can be attached under tension to a wall or a ceiling.

[0041] In one embodiment, the method may comprise the step of securing, fastening, or directly attaching the vibrator to the flask at a vibrator position. The more firmly attached and connected the vibrator is to the flask, the better the vibrations will be transferred to the flask, as the vibrator, flask and mould material becomes a unified system.

[0042] In one embodiment, the vibrator may be a vibration motor, such as a vibratory stress relief apparatus, which may be configured to provide a specific vibrating frequency. This type of motor may allow for controlled and consistent vibrations that are essential for effective removal of mould material from the flask. The use of a vibratory stress relief apparatus may further indicate that the system is equipped to handle robust vibrations, which may help in loosening even densely packed mould materials.

[0043] In one embodiment, the at least one vibration frequency may deviate by 6 Hz or less, preferably by 5 Hz or less, more preferably by 4 Hz or less, further more preferably by 3 Hz or less, even more preferably by 2 Hz or less, even more preferably by 1 Hz or less, and most preferably by 0.5 Hz or less from a resonance frequency of the system. For removal of moulding material from flasks used in the production of large components, such as, but not limited to, wind turbine components, the at least one vibration frequency preferably deviates by 4 Hz or less from the resonance frequency of the system. When the vibrator is attached to a large flask, used e.g. for moulding wind turbine components, and vibrates at a frequency deviating by 4 Hz or less from the resonance frequency of the system, the system oscillates with large amplitudes sufficient to remove even tightly adhering mould material from the large flask. Even though, the system is vibrating close to the resonance frequency, the movements of the flask are below plastic deformation and any structural deformation of the flask over time will not occur due to the vibrations. Being close to the resonance frequency also means that the time necessary for removing the mould material from the flask will be reduced, down one third of the time required using a vibrational table. P7396PC00

[0044] 8

[0045] Applying the at least one vibration frequency at or close to the resonance of the system significantly enhances the efficiency of mould material removal. When the system vibrates at the resonant frequency, even minimal energy input generates maximum amplitude vibrations, causing the entire structure to oscillate intensely.

[0046] Resonant frequency vibration also improves the uniformity of mould material removal, particularly beneficial for complex flask geometries or castings with intricate surfaces. By targeting the resonant frequency, operators can achieve more thorough cleaning, especially in areas where mould material might otherwise remain tightly packed.

[0047] Additionally, this approach can minimize wear on equipment, as lower input forces achieve the desired effect, and can reduce the likelihood of damage to the flask and the flask surface.

[0048] In one embodiment, the at least one vibration frequency may be changed or increased as the mould material is removed from the flask. When the mould material is removed from the flask, the total mass of the system will decrease, and the resonance frequency will change. By changing or increasing the at least one vibration frequency as the mould material is removed from the flask, the at least one vibration frequency may continuously be kept at or close to the resonance frequency.

[0049] In one embodiment, at least one of the frequencies transmitted by the vibrator may be below 500 Hz, and preferably below 250 Hz. Lower frequencies may be beneficial in this context as they may penetrate deeper into the mould material and may provide a higher amplitude in the vibrations, causing a more thorough loosening and removal process. By operating at these frequencies, the method may ensure that vibrations are adequately transmitted throughout the flask without causing excessive stress or damage to the flask itself.

[0050] In one embodiment, the method may comprise the step of scanning the vibration frequency from a first frequency to a second frequency, thereby determining a resonance frequency of the system. The method may comprise a vibration sensor that measures the vibration, so that the resonance frequency can be determined. The vibrator may comprise the vibration sensor. Such a process can be beneficial, as the process enables a user to find the resonance frequency of the system and therefore pick a certain vibration frequency for the vibrator. In addition, as the mould material is P7396PC00

[0051] 9

[0052] removed from the flask, the weight of the system is decreasing. As a result, the resonance frequency can also be affected. The vibrator frequency may be tuned depending on the change of the resonance frequency of the system, in order to optimize the mould material removal process, as frequencies close to the resonance frequency lead to larger oscillations, which in turn cause swifter removal of the mould material. During removal of the mould material, the vibrator frequency may be increased, since in general the resonance frequency of the system will increase as the mould material is removed from the flask.

[0053] For example, the frequency of the vibrator may be swept from 0.1 Hz to 100 Hz with a step size of 0.5 Hz. Different step sizes may also be used, such as 0.1 Hz, 0.2 Hz or 1 Hz. A device can be used to measure the amplitude of oscillations of the flask, determining the resonance frequency. Such values may be stored in a database and used in the method in order to optimize the removal of the mould material.

[0054] In one embodiment, the first frequency is preferably lower than 10 Hz, more preferably lower than 1 Hz, and wherein the second frequency is larger than 10 Hz, more preferably larger than 100 Hz, even more preferably larger than 500 Hz. The second frequency may be smaller than 200 Hz. The frequency spectrum between the first frequency and the second frequency can depend on the specifics of each system, as the resonance frequency depends on its physical characteristics, such as size, shape, mass, density, and the material of the flask and / or the mould material. As a result, depending on the specifics of each system, different ranges of frequencies may be used. For a very large and heavy object, a lower resonance frequency is expected, and the first and second frequencies may be chosen accordingly.

[0055] In one embodiment, the method may comprise attaching the vibrator to a second vibrator position on the flask, different from the initial vibrator position, for transmitting frequencies. This flexibility in positioning may allow the vibrations to be applied from various angles or positions on the flask, increasing the effectiveness of mould material removal by addressing different areas of the flask, so that the mould material in the flask that could not be removed in the initial vibrator position may be removed when the vibrator is attached to the flask at the second vibrator position. P7396PC00

[0056] 10

[0057] In one embodiment, the attachment of the vibrator to a second vibrator position occurs after activating the vibrator. Such a feature can be advantageous, as a user may realize that the vibrator position does not produce the expected results. Hence, the user may remove the vibrator and attach it on a different location on the flask, in order to optimize the mould material removal. Specifically, as described herein, during the removal of mould material, the resonance frequency is changing. As a result, the position of the vibrator may also not be as effective. Hence, it may be beneficial to reposition the vibrator on a different position of the flask. The vibrator may have to be turned off before moving the vibrator and turned on again after the move.

[0058] In one embodiment, the method may comprise attaching a second vibrator to a different position on the flask and activating the second vibrator to transmit additional frequencies. Providing two vibrators may be advantageous in cases where the mould material is particularly dense and / or where the flask design requires vibrations from multiple angles, and / or where the time for removing the mould material should be as low as possible. If the second vibrator is also tuned to emit frequencies at or close to the resonance frequency, the mould material can be removed faster. By having two vibrators, there may be less corners, where the mould material will not disengage from the flask.

[0059] In one embodiment, the second vibrator may transmit frequencies that may be the same or different from those of the first vibrator. This flexibility may allow for the customisation of the vibration process based on the specific characteristics of the mould material and the flask. Using identical or complementary frequencies may enhance the synchronisation of the vibrations, while differing frequencies might address particular problem areas within the flask.

[0060] In one embodiment, the method may comprise providing information or data about the mould material and / or the flask — such as volumetric, geometric, and / or material characteristics — to a model, along with initial frequency and fixation data. The model may be a software model, like e.g. the finite element method (FEM) and / or the Modal Analysis Method and / or the Harmonic Analysis Method. This data may then be used to receive feedback from the model, which may help in determining optimal vibrator positions, frequencies, and fixation points. This model-based approach may provide insights to fine-tune the vibration process, resulting in a more efficient and targeted P7396PC00

[0061] 11

[0062] removal of mould material. The use of the model does not simply relate to data communication from the mould material and the flask to a model. As described herein, the model can use such data in order to predict various parameters, such as resonance frequency, and determine optimal vibrator positions, frequencies and fixation points. An optimal frequency may be a frequency that is close to the resonance frequency of the system, and / or a frequency that provides a relatively large amplitude in a volume of the flask, where the mould material is difficult to be released from the flask. The optimal vibrator position and fixation point may be defined as the arrangement that provides the maximum achievable vibration amplitude and energy transmission to a predetermined target region, in a mode shape most suitable for the specific mould material removal and its spatial position. The target region may be a region of the flask or of the mould material, where the mould material is the most difficult to remove. In practical embodiments, fixation points are preferably positioned in structurally rigid areas, whereas the vibrator is disposed at positions exhibiting greater flexibility to promote efficient excitation of the desired vibrational mode. For example, in the case of a substantially triangular or polygonal flask geometry, fixation points may be positioned at or near the more rigid vertices of the triangle or polygon, while one or more vibrator positions may be disposed along the more flexible side regions of the flask body to optimize energy transfer and mode shape formation. In contrast to state of the art solutions, the model described herein does not simply obtain measurements from the flask or the vibrator for monitoring purposes. The model uses such data to optimize the method of mould material removal, by determining an optimal location for positioning the vibrator, its frequencies and fixation points.

[0063] FEM is a general numerical method for solving partial differential equations in two- or three-space variables. To solve a problem, such as how to optimize mould material removal for a flask, FEM can subdivide a large system into smaller, simpler parts called finite elements. This can be achieved by a particular space discretization in the space dimensions, which can be implemented by the construction of a mesh of the object: the numerical domain for the solution that has a finite number of points.

[0064] In one embodiment, the mould material and flask information provided to the model may comprise details about the locations of the walls surrounding the cavities, the stiffness of these walls, and the mass of the mould materials. This detailed information may allow the model to account for the specific structural and material properties of the P7396PC00

[0065] 12

[0066] flask, enabling more precise adjustments to the vibration process, and provide a more accurate model and model output. By considering factors such as wall stiffness and mould mass, the model may optimise the vibration settings to ensure thorough mould material removal while minimising potential damage to the flask.

[0067] In one embodiment, the material information comprises geometries, like height, width, and / or thickness, weight, and / or density information of the mould material, and wherein the flask information comprises geometries, weight, and / or density information of the flask. Such information can be beneficial to be included into the model, in order to acquire a realistic simulation of the flask and the mould material. For example, the model can be utilized in order to estimate the amount of mould material that can be used, the type of mould material. The model may also be utilized in order to estimate the resonance frequency of the flask, and the change of the resonance frequency as the mould material is removed from the flask. Further, the model may be used to estimate the optimal locations that the vibrator can be attached on the flask, in order to optimize the mould material removal process.

[0068] In one embodiment, the model may be configured to predict a removal time for a given initial fill level and grain size of the mould material, and to select a frequency sweep that tracks the resonance shift or resonance increase as mass is reduced, thereby improving the mould material removal process. The model may represent the system by using a finite element model that resolves mode shapes, i.e. the spatial patterns of vibration for each natural frequency. In an embodiment, sensor inputs from accelerometers, or load cells may be used to identify parameters during the execution of the method, after which the model may update an estimate of remaining mass and adjust the vibrator amplitude, frequency, and attachment position. The model may also propose using two or more vibrators with phase control, or a sequence of attachment points aligned to predicted nodal lines of the dominant mode, to avoid dead zones and bridging. The output may include constraints that prevent exciting natural frequencies of the support frame, recommendations for flask orientation and clamping stiffness, and a termination criterion when a measured response matches a low-mass signature, which may reduce cycle time, power consumption, and mechanical wear while lowering acoustic emissions.

[0069] Description of the drawings P7396PC00

[0070] 13

[0071] The disclosure will in the following be described in greater detail with reference to the accompanying drawings:

[0072] Fig. 1 a schematic view of a flask

[0073] Fig. 2 a schematic view of a flask segment

[0074] Fig. 3 a schematic view of a vibrator

[0075] Fig. 4 a schematic view of a flask segment with a vibrator attached to the flask segment

[0076] Detailed description of the disclosure

[0077] Fig. 1 shows a flask 2 used e.g. in a moulding or casting process. The flask comprises several cavities 8 defined by an outer wall 4 and inner walls 6. Before casting, the cavities 8 can be filled with mould material such as sand for defining the geometry of a component to be formed. To withstand the pressure from the liquid to become the component during the solidification process, the mould material has to be well compacted. That means that the mould material is difficult to remove from the outer walls and the inner walls afterwards. Removing the mould material by targeted vibrations reduces the time to clean the flask.

[0078] Fixation points 10 are shown, which may be used to secure the flask during vibration. In this embodiment, isolators 12 are also depicted, which may be chains or straps so that one or more sides of the flask can be attached under tension to a wall or a ceiling. The isolators may be blocks so that the flask can be clamped between two walls or between the ceiling and the floor.

[0079] Fig. 2 shows a sectional view of the flask - a flask segment 2’. The flask segment has two cavities 8, where the left cavity is still filled by mould material or sand 14, while the right cavity has been emptied. The outer wall 4 and inner walls 6 define these cavities.

[0080] Fig. 3 shows a vibrator 16 designed for attachment to the flask. The vibrator may have a motor (not shown) driving an unbalanced mass (not shown) for providing the vibrations. The vibrator may comprise a foot 18 with openings (not shown), so that the vibrator may be screwed onto a flask to facilitate secure positioning. The vibrator may comprise another plate (not shown), so that the foot and the plate can clamp a part of the flask for connecting the vibrator to the flask. This attachment allows the vibrator to P7396PC00

[0081] 14

[0082] transmit specific frequencies to the flask, aiding in the removal of mould material from the cavities 8.

[0083] Fig. 4 shows a sectional view of the flask - a second flask segment 2” - where a vibrator 16 is attached to a structural flange 20. The second flask segment 2” comprises an attachment 22, preferably attached to the structural flange 20 by welding or bolting. The attachment 22 comprises a threaded rod 24 and a nut 26 that keeps the vibrator 16 well attached to the structural flange 20 and the flask, so that the vibrations from the vibrator can be well transferred to the flask. A second attachment (not shown), a second threaded rod (not shown) and a second nut (not shown) will in the same way attach the right side of the vibrator to the structural flange 20. The attachment or another attachment may likewise be welded to the flask at another position and not necessarily to a flange. The flask may have several attachments at different locations for providing different options for the location of the vibrator, so that the optimal position for the vibrator always can be chosen depending on the amount of mould material or sand in the flask for a particular item being cast and the dynamics of the system.

[0084] Instead of or in addition to the attachment(s), the threaded rod(s), and the nut(s), the vibrator may be clamped to the flask by one or more clamps, preferably metal clamps. That will provide a flexible solution, where the vibrator can be positioned in principle anywhere on the flask. The vibrator may also be clamped to a second attachment welded or bolted to the flask, where the second attachment may provide one or more suitable plate(s), so that the vibrator or a foot of the vibrator can be clamped with the plate(s).

[0085] Reference list:

[0086] 2 - Flask

[0087] 2’ - Flask segment

[0088] 2” - Second flask segment

[0089] 4 - Outer wall

[0090] 6 - Inner wall

[0091] 8 - Cavity

[0092] 10 - Fixation

[0093] 12 - Isolator

[0094] 14 - Mould material, e.g. sand P7396PC00

[0095] 15

[0096] 16- Vibrator

[0097] 18 - Foot

[0098] 20 - Structural flange

[0099] 22 - Attachment

[0100] 24 - Threaded rod

[0101] 26 - Nut

[0102] Items

[0103] 1. A method for removing mould material from a flask for producing or forming a component, wherein the method comprises

[0104] - providing a flask comprising one or more cavities filled with mould material,

[0105] - providing a vibrator configured to generate a vibration at at least one vibration frequency with a vibration amplitude,

[0106] - attaching the vibrator to the flask at a vibrator position, and

[0107] - activating the vibrator for transmitting the at least one frequency to the flask and the mould material for removing the mould material from the flask.

[0108] 2. The method according to item 1 , wherein one, two, three, or more fixation(s) is / are positioned underneath and / or on and / or attached to the flask at one, two, three, or more fixation position(s).

[0109] 3. The method according to item 2, wherein at least some of the one, two, three, or more fixation(s) is / are one, two, three, or more isolator(s).

[0110] 4. The method according to any one of the preceding items, comprising the step of securing, fastening, or directly attaching the vibrator to the flask at a vibrator position.

[0111] 5. The method according to any one of the preceding items, wherein the vibrator is attached on top of or on the side of the flask.

[0112] 6. The method according to any one of the preceding items, wherein the vibrator has one or more sides, like outward orienting planar side(s), preferably pointing P7396PC00

[0113] 16

[0114] in different directions, and the vibrator is attached to the flask so that not more than three of the sides are touching the flask, preferably not more than two of the sides are touching the flask or most preferably not more than one side is touching the flask, when the vibrator is activated.

[0115] 7. The method according to any of the preceding items, wherein the vibrator is a vibration motor, like a vibratory stress relief apparatus, configured to provide a vibrating frequency.

[0116] 8. The method according to any of the preceding items, wherein the at least one vibration frequency deviates by 4 Hz or less, preferably by 3 Hz or less, preferably by 2 Hz or less, even more preferably by 1 Hz or less, and most preferably by 0.5 Hz or less from a resonance frequency of a system comprising the flask with the mould material and the vibrator attached to the flask.

[0117] 9. The method according to any of the preceding items, wherein the at least one vibration frequency is changed or increased during the removal of the mould material from the flask.

[0118] 10. The method according to any of the preceding items, wherein at least one of the one or more frequencies is below 500 Hz, preferably below 250 Hz.

[0119] 11. The method according to any one of the preceding items, further comprising the step of scanning the vibration frequency from a first frequency to a second frequency, thereby determining a resonance frequency of the system.

[0120] 12. The method according to item 11 , wherein the first frequency is preferably lower than 10 Hz, more preferably lower than 1 Hz, and wherein the second frequency is larger than 10 Hz, more preferably larger than 100 Hz, even more preferably larger than 500 Hz.

[0121] 13. The method according to any of the preceding items, wherein the method

[0122] comprises P7396PC00

[0123] 17

[0124] attaching the vibrator to a second vibrator position different from the vibrator position for transmitting the one or more frequencies at the second vibrator position.

[0125] 14. The method according to item 13, wherein the attachment of the vibrator to a second vibrator position occurs after activating the vibrator.

[0126] 15. The method according to any of the preceding items, wherein the method comprises

[0127] - attaching a second vibrator to the flask at a second vibrator position, and

[0128] - activating the second vibrator for transmitting one or more second frequencies for removing the mould material from the flask.

[0129] 16. The method according to any of items 11-15, wherein at least one, some, or all of the one or more second frequencies is / are the same as the one or more frequencies, and / or wherein at least one, some, or all of the one or more second frequencies is / are different from the one or more frequencies.

[0130] 17. The method according to any of the preceding items, wherein the method comprises

[0131] - providing mould material information and / or flask information and / or vibrator information to a model, and

[0132] - receiving received data from the model,

[0133] wherein the vibrator position, and / or the vibration frequency, and / or the vibration amplitude is selected based on the received data optionally for optimally removing mould material from a flask, like optimally removing all mould material from the flask.

[0134] 18. The method according to item 17, wherein the mould material information comprises volumetric, and / or geometric, and / or material characteristics of the mould material, and / or the flask information comprises volumetric, and / or geometric, and / or material characteristics of the flask. P7396PC00

[0135] 18

[0136] 19. The method according to item 2 and item 17 or 18, wherein the fixation position(s) is / are selected based on the received data.

[0137] 20. The method according to any one of items 17-19, wherein the material information comprises geometries, weight, and / or density information of the mould material, and wherein the flask information comprises geometries, weight, and / or density information of the flask.

[0138] 21. The method according to any of the items 17-20, wherein the method comprises

[0139] - providing mould material and flask information about the mould material and / or the flask to a model, wherein preferably the mould material and flask information comprises volumetric, and / or geometric, and / or material characteristics of the mould material and / or of the flask, - providing vibrator information about an initial frequency range of the vibrator to the model, and / or an initial fixation information about one, two, three, or more initial fixation position(s) of the one, two, three, or more fixation(s) to the model, and

[0140] - receiving received data from the model connected with vibrational amplitudes in different vibrational positions on the flask

[0141] wherein the vibrator position and / or the one or more frequencies of the vibrator and / or the one, two, three, or more fixation position(s) is / are determined based on the received data.

[0142] 22. The method according to any of the item 17-21, wherein the mould material and flask information comprises information related to

[0143] - locations of walls surrounding the cavities,

[0144] - stiffness of the walls, and / or

[0145] - mass of the mould materials in the cavities.

[0146] 23. The method according to any of the preceding items, wherein the flask with the mould material has a mass of at least 500 kg.

Claims

1. P7396PC002.193.Claims1. A method for removing mould material from a flask for producing or forming a component, wherein the method comprises5.- providing a flask comprising one or more cavities filled with mould material,6.- providing a vibrator configured to generate a vibration at at least one vibration frequency with a vibration amplitude,7.- attaching the vibrator to the flask at a vibrator position, and8.- activating the vibrator for transmitting the at least one frequency to the flask and the mould material for removing the mould material from the flask,9.wherein the at least one vibration frequency deviates by 4 Hz or less from a resonance frequency of a system comprising the flask with the mould material and the vibrator attached to the flask.

2. The method according to claim 1 , wherein one, two, three, or more fixation(s) is / are positioned underneath and / or on and / or attached to the flask at one, two, three, or more fixation position(s).

3. The method according to claim 2, wherein at least some of the one, two, three, or more fixation(s) is / are one, two, three, or more isolator(s).

4. The method according to any one of the preceding claims, comprising the step of securing, fastening, or directly attaching the vibrator to the flask at a vibrator position.

5. The method according to any one of the preceding claims, wherein the vibrator is attached on top of or on the side of the flask.

6. The method according to any one of the preceding claims, wherein the vibrator has one or more sides, like outward orienting planar side(s), preferably pointing in different directions, and the vibrator is attached to the flask so that not more than three of the sides are touching the flask, preferably not more than two ofP7396PC0015.2016.the sides are touching the flask or most preferably not more than one side is touching the flask, when the vibrator is activated.

7. The method according to any of the preceding claims, wherein the vibrator is a vibration motor, like a vibratory stress relief apparatus, configured to provide a vibrating frequency.

8. The method according to any of the preceding claims, wherein the at least one vibration frequency deviates by 3 Hz or less, preferably by 2 Hz or less, more preferably by 1 Hz or less, most preferably by 0.5 Hz or less from a resonance frequency of a system comprising the flask with the mould material and the vibrator attached to the flask.

9. The method according to any of the preceding claims, wherein the at least one vibration frequency is changed or increased during the removal of the mould material from the flask.

10. The method according to any of the preceding claims, wherein at least one of the one or more frequencies is below 500 Hz, preferably below 250 Hz.

11. The method according to any one of the preceding claims, further comprising the step of scanning the vibration frequency from a first frequency to a second frequency, thereby determining a resonance frequency of the system.

12. The method according to claim 11 , wherein the first frequency is preferably lower than 10 Hz, more preferably lower than 1 Hz, and wherein the second frequency is larger than 10 Hz, more preferably larger than 100 Hz, even more preferably larger than 500 Hz.

13. The method according to any of the preceding claims, wherein the method comprises24.- attaching the vibrator to a second vibrator position different from the vibrator position for transmitting the one or more frequencies at the second vibrator position. P7396PC0025.2114. The method according to claim 13, wherein the attachment of the vibrator to a second vibrator position occurs after activating the vibrator.

15. The method according to any of the preceding claims, wherein the method comprises28.- attaching a second vibrator to the flask at a second vibrator position, and29.- activating the second vibrator for transmitting one or more second frequencies for removing the mould material from the flask.

16. The method according to any of claims 11-15, wherein at least one, some, or all of the one or more second frequencies is / are the same as the one or more frequencies, and / or wherein at least one, some, or all of the one or more second frequencies is / are different from the one or more frequencies.

17. The method according to any of the preceding claims, wherein the method comprises32.- providing mould material information and / or flask information and / or vibrator information to a model, and33.- receiving received data from the model,34.wherein the vibrator position, and / or the vibration frequency, and / or the vibration amplitude is selected based on the received data optionally for optimally removing mould material from a flask, like optimally removing all mould material from the flask.

18. The method according to claim 17, wherein the mould material information comprises volumetric, and / or geometric, and / or material characteristics of the mould material, and / or the flask information comprises volumetric, and / or geometric, and / or material characteristics of the flask.

19. The method according to claim 2 and claim 17 or 18, wherein the fixation position(s) is / are selected based on the received data.

20. The method according to any one of claims 17-19, wherein the material information comprises geometries, weight, and / or density information of theP7396PC0038.2239.mould material, and wherein the flask information comprises geometries, weight, and / or density information of the flask.

21. The method according to any of the claims 17 - 20, wherein the method comprises41.- providing mould material and flask information about the mould material and / or the flask to a model, wherein preferably the mould material and flask information comprises volumetric, and / or geometric, and / or material characteristics of the mould material and / or of the flask, - providing vibrator information about an initial frequency range of the vibrator to the model, and / or an initial fixation information about one, two, three, or more initial fixation position(s) of the one, two, three, or more fixation(s) to the model, and42.- receiving received data from the model connected with vibrational amplitudes in different vibrational positions on the flask43.wherein the vibrator position and / or the one or more frequencies of the vibrator and / or the one, two, three, or more fixation position(s) is / are determined based on the received data.

22. The method according to any of the claim 17 - 21, wherein the mould material and flask information comprises information related to45.- locations of walls surrounding the cavities,46.- stiffness of the walls, and / or47.- mass of the mould materials in the cavities.

23. The method according to any of the preceding claims, wherein the flask with the mould material has a mass of at least 500 kg.

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