Flask molding machine

Abstract

This flask molding machine comprises: a squeeze plate which has a main surface that defines a molding space and that has a plurality of openings; a plurality of segment feet which are disposed in the plurality of openings and which can move toward the molding space from the main surface of the squeeze plate; and a plurality of segment cylinders which correspond to the plurality of segment feet, which are each connected to a respective segment foot, and the strokes of which are adjustable in a stepless manner.

Description

Flask molding machine

[0001] This disclosure relates to a flask molding machine.

[0002] Patent Document 1 discloses a flask molding machine. A flask molding machine is a molding machine that molds in a state with a casting flask. In a flask molding machine, a molding space is defined by a lid member, a cope, a casting flask, and a pattern. Sand is filled into the molding space, and the sand is squeezed when the lid member descends. A plurality of segment feet that can be controlled to stop ascending and descending by supplying and exhausting compressed air penetrate through the lid member. The plurality of segment feet can be adjusted in three stages: an upper end position, a lower end position, and a middle descending position.

[0003] Japanese Patent Application Laid-Open No. 2001-129641

[0004] In the flask molding machine described in Patent Document 1, by adjusting the height of a plurality of segment feet according to the unevenness of the pattern, the sand thickness (height) in the casting flask and the cope is made uniform, and uniform compression is realized as a whole. However, in the flask molding machine described in Patent Document 1, it is difficult to finely adjust the height of the segment feet so as to be in an optimal position according to the shape of the pattern. For this reason, the mold strength may vary depending on the location of the pattern, and there is a risk that the molding quality may not be stable. This disclosure provides a technique for suppressing variations in mold strength in a flask molding machine.

[0005] A flask molding machine according to one aspect of this disclosure includes a squeeze plate having a main surface that defines a molding space, the main surface having a plurality of openings, a plurality of segment feet disposed in the plurality of openings, each segment foot being movable from the main surface of the squeeze plate toward the molding space, a plurality of segment cylinders corresponding to the plurality of segment feet, each segment cylinder being connected to each segment foot and capable of adjusting the stroke amount steplessly.

[0006] According to this disclosure, a technique for suppressing variations in the mold strength of sand in a flask molding machine is provided. ⏎

[0007] Figure 1 is a partial cross-sectional view illustrating the molding space definition process in a framed molding machine according to one embodiment. Figure 2 is a partial cross-sectional view illustrating the sand filling process in the framed molding machine shown in Figure 1. Figure 3 is a partial cross-sectional view illustrating the squeeze process in the framed molding machine shown in Figure 1. Figure 4 is a partial cross-sectional view illustrating an example of a segment foot. Figure 5 is a partial cross-sectional view illustrating an example of a segment foot. Figures 6(A) to (D) illustrate an example of the pattern shape and segment foot height.

[0008] Embodiments of the present disclosure will be described in detail below with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant descriptions are omitted. The dimensional ratios in the drawings do not necessarily correspond to those in the description. The terms "top," "bottom," "left," and "right" are based on the illustrated state and are for convenience only. In the drawings, the X and Y directions are horizontal, and the Z direction is vertical.

[0009] [Overview of a framed molding machine] Figure 1 is a partial cross-sectional view illustrating the molding space definition process in a framed molding machine according to one embodiment. The framed molding machine 1 is a molding machine that molds a mold with a frame. As shown in Figure 1, the framed molding machine 1 includes a frame setting station R1 and a filling and compression station R2. The metal frame 10 located in the filling and compression station R2 is first brought into the frame setting station R1. The metal frame 10 is a box-shaped frame with openings at the upper and lower ends. In the frame setting station R1, the metal frame 10 is frame-set on the model (pattern). Frame setting means aligning the metal frame 10 with the pattern. The metal frame 10 set on the pattern is brought into the filling and compression station R2, which is arranged in parallel with the frame setting station R1. In the filling and compression station R2, sand is filled into the metal frame 10. The sand filled in the metal frame 10 is compressed from above and below by a squeeze mechanism provided in the filling and compression station R2 to form a mold. Subsequently, the mold within the metal frame 10 is removed from the apparatus. In this way, the framed molding machine 1 molds a mold with a frame. The framed molding machine 1 may mold the upper mold and the lower mold alternately, or it may mold either the upper mold or the lower mold. Below, a molding machine that molds the upper mold and the lower mold alternately will be described as an example.

[0010] The details of the frame-type molding machine 1 are described below. The frame-type molding machine 1 includes a frame 2. The frame 2 supports the components present in the frame setting station R1 and the filling and compression station R2. The frame setting station R1 is provided with a frame setting cylinder 11 fixed to the frame 2. The frame setting cylinder 11 moves the metal frame brought into the frame setting station R1 up and down to set it in the pattern, and also moves the metal frame with the mold formed in the filling and compression station R2 up and down. Figure 1 shows how the frame setting cylinder 11 moves the metal frame 10A with the mold formed in it.

[0011] A turntable 12 is positioned at the frame setting station R1 and the filling and compression station R2. The turntable 12 has a body 13 and a rotating part 14. The body 13 is a frame and includes a first end 15 and a second end 15A. A first pattern 16 for the upper mold is positioned at the first end 15, and a second pattern 16A for the lower mold is positioned at the second end 15A. The rotating part 14 is provided in the center of the body 13 and supports the body 13 so that it can rotate around a rotation axis in the vertical direction. By rotating the body 13 180 degrees around the rotation axis, the second end 15A can be moved from the frame setting station R1 to the filling and compression station R2, and the first end 15 can be moved from the filling and compression station R2 to the frame setting station R1.

[0012] When the metal frame 10 is frame-set onto the pattern at the frame-setting station R1, the turntable 12 positions its first end 15 on the frame-setting station R1. The metal frame 10, having been brought into the frame-setting station R1, is moved downward by the frame-setting cylinder 11 and placed on the turntable 12 to be combined with the pattern. In the example shown in Figure 1, the metal frame 10 is combined with the first pattern 16 for the upper mold. Subsequently, the turntable 12 rotates 180 degrees, transporting the frame-set metal frame 10 and the first pattern 16 to the filling and compression station R2.

[0013] A first leveling frame 17 and a second leveling frame 17A are provided at the first end 15 and second end 15A of the turntable 12. Frame fixing brackets may also be provided on the turntable 12. The frame fixing brackets are positioned at four locations on the turntable 12, corresponding to the four corners of the metal frame 10. The frame fixing brackets are positioned to support the metal frame 10 after it has been cut out, and prevent interference between the pattern and the mold.

[0014] A sand tank 18 is fixed to the upper part of the frame 2 at the filling and compression station R2. The sand tank 18 stores sand inside for supply to the metal frame 10. The upper and lower ends of the sand tank 18 are open. A slide gate is provided at the upper end of the sand tank 18, which slides a plate-shaped shielding member horizontally. The upper end of the sand tank 18 is configured to be openable and closable by the operation of the slide gate. A chute (not shown) for introducing sand is located above the sand tank 18, and sand is supplied to the sand tank 18 via the chute.

[0015] The lower end of the sand tank 18 is bifurcated, and a sand slab 19 is fixed inside the bifurcated structure. The sand slab 19 is a box-shaped frame with open upper and lower ends. The lower end of the sand slab 19 is configured to be connectable to the upper end of the metal frame. In the example shown in Figure 1, the sand slab 19 is connected to the metal frame 10. A nozzle is provided on the side of the sand slab 19, and the lower end of the sand tank 18 is connected to the nozzle. The sand tank 18 is connected to a compressed air source (not shown), and compressed air at a predetermined pressure is supplied to the sand tank 18. When the slide gate is closed, the compressed air supplied from the top of the sand tank 18 is sent towards the bottom of the sand tank 18. The sand in the sand tank 18 is supplied into the sand slab 19 along with the compressed air.

[0016] An upper squeeze plate 20 (an example of a squeeze plate) is positioned inside the bifurcated structure of the sand tank 18. The upper squeeze plate 20 is a plate-shaped member whose lower surface (an example of a main surface) is the surface to be squeezed. The upper squeeze plate 20 is supported so as to be movable in the vertical direction by an upper squeeze cylinder 21 fixed to the frame 2, and moves up and down in accordance with the operation of the upper squeeze cylinder 21. The upper squeeze plate 20 is approximately the same size as the opening of the hoarding frame 19. By moving downward, the upper squeeze plate 20 moves from the upper end side of the hoarding frame 19 to the lower end side of the hoarding frame 19, and by moving upward, it moves from the lower end side of the hoarding frame 19 to the upper end side of the hoarding frame 19. In this way, the upper squeeze plate 20 is configured to be movable in the vertical direction within the hoarding frame 19.

[0017] Multiple openings are formed on the lower surface of the upper squeeze plate 20, and multiple segment feet 22 that can protrude according to the shape of the pattern are arranged in these openings. The operation of the multiple segment feet 22 equalizes the strength of the mold. Details of the segment feet 22 will be described later.

[0018] In the filling and compression station R2, the end of the turntable 12 is located below the mold 19. In the example shown in Figure 1, the first end 15 is located below the mold 19. Below the end of the turntable 12, a table 23 is positioned between it and the upper squeeze plate 20, sandwiching the mold 19, the metal frame, the pattern, and the end of the turntable 12. In the example shown in Figure 1, below the first end 15, the table 23 is positioned between it and the upper squeeze plate 20, sandwiching the mold 19, the metal frame 10, the first pattern 16, and the first end 15. In other words, the lower surface of the upper squeeze plate 20 and the upper surface of the table 23 are positioned facing each other. The table 23 is supported so as to be movable in the vertical direction by a lower squeeze cylinder 24 fixed to the frame 2, and moves up and down in accordance with the operation of the lower squeeze cylinder 24.

[0019] The molding space S of the mold is defined by the lower surface of the upper squeeze plate 20, the molding frame 19, the metal frame, and the upper surface of the pattern. In the example shown in Figure 1, it is defined by the lower surface of the upper squeeze plate 20, the molding frame 19, the metal frame 10, and the upper surface of the first pattern 16. The molding space S is formed when the upper squeeze cylinder 21 is operated to move the upper squeeze plate 20 downward and into the molding frame 19, while the lower squeeze cylinder 24 is operated to move the ends of the metal frame 10, the pattern, and the turntable 12 upward together, and the upper end of the metal frame connects to the lower end of the molding frame 19. In the example shown in Figure 1, the molding space S is formed when the upper squeeze cylinder 21 is operated to move the upper squeeze plate 20 downward, while the lower squeeze cylinder 24 is operated to move the metal frame 10, the first pattern 16, and the first end 15 upward together, and the upper end of the metal frame 10 connects to the lower end of the molding frame 19.

[0020] Figure 2 is a partial cross-sectional view illustrating the sand filling process in the frame-type molding machine 1. As shown in Figure 2, the molding space S is filled with sand stored in the sand tank 18 via the molding frame 19. A new metal frame 10B is also brought into the frame setting station R1.

[0021] Figure 3 is a partial cross-sectional view illustrating the squeeze process in the framed molding machine 1. As shown in Figure 3, the upper squeeze cylinder 21 moves the upper squeeze plate 20 so that the distance between the upper squeeze plate 20 and the table 23 changes while the molding space is filled with sand. Specifically, the upper squeeze cylinder 21 moves the upper squeeze plate 20 downward. The lower squeeze cylinder 24 moves the table 23 so that the distance between the upper squeeze plate 20 and the table 23 changes while the molding space is filled with sand. Specifically, the lower squeeze cylinder 24 moves the table 23 upward. This causes squeezing on the upper squeeze plate 20 and the table 23 (the upper surface of the pattern). Pressure is applied to the sand in the molding space, and the mold is formed.

[0022] [Control Device] The framed molding machine 1 may be equipped with a control device 30. The control device 30 is a computer equipped with a control unit such as a processor, a storage unit such as memory, an input / output unit such as an input device and a display device, and a communication unit such as a network card. It is electrically connected to and controls various parts of the framed molding machine 1, such as the mold sand supply system, compressed air supply system, drive system and power supply system. The control device 30 allows an operator to input commands to manage the framed molding machine 1 using the input device, and the display device can visualize and display the operating status of the framed molding machine 1. Furthermore, the storage unit of the control device 30 stores control programs for controlling various processes performed by the framed molding machine 1 using the processor, and programs for executing processes in each component of the framed molding machine 1 according to the molding conditions.

[0023] [Details of Segment Foot] Figures 4 and 5 are partial cross-sectional views illustrating an example of a segment foot. As shown in Figures 4 and 5, the lower surface 20a (an example of the main surface) of the upper squeeze plate 20 defines the molding space S. Multiple openings 20b are formed in the lower surface 20a. Here, as an example, six openings are formed. Multiple segment feet are arranged in the multiple openings 20b. Here, the first segment foot 22A, the second segment foot 22B, the third segment foot 22C, the fourth segment foot 22D, the fifth segment foot 22E, and the sixth segment foot 22F are arranged in the corresponding openings. Each segment foot is configured to be movable from the lower surface 20a of the upper squeeze plate 20 toward the molding space S.

[0024] The multiple segment feet 22 are the tips of the corresponding multiple segment cylinders 26. Each segment cylinder and each segment foot is supported by the upper squeeze plate 20. Each segment foot is independently operable. Each segment cylinder operates by a hydraulic circuit, for example. Each segment cylinder may also be pneumatically or electrically operated.

[0025] The upper squeeze plate 20 is equipped with multiple displacement sensors 27 for detecting the stroke amount of multiple segment cylinders 26. Note that only one displacement sensor is shown in Figures 4 and 5, and the remaining five are omitted from the illustration. In other words, there is a one-to-one pair between the segment cylinder and the displacement sensor. One example of the multiple displacement sensors 27 is a laser displacement sensor.

[0026] The control device 30 is connected to a plurality of segment cylinders 26 and a plurality of displacement sensors 27, and adjusts the stroke amount of each segment cylinder so that the stroke amount detected by each displacement sensor approaches the target value of each segment cylinder. This makes it possible to adjust the stroke amount of each segment cylinder steplessly. In other words, the control device 30 can control each segment cylinder so that the position of the tip of each segment foot is at any position in the molding space S.

[0027] Multiple segment cylinders 26 may operate according to the shape of the pattern. For example, as shown in Figure 5, the second segment foot 22B, third segment foot 22C, fourth segment foot 22D, and fifth segment foot 22E are moved downward to match the shape (height) of the first pattern 16.

[0028] The control device 30 may store a relationship between the pattern defining the molding space S and the target stroke amount of each segment cylinder. For example, in the case of a pattern with identifier AA, identifier AA and the stroke amount XX of the segment cylinders corresponding to the second segment foot 22B and the third segment foot 22C are stored in association. In the case of a pattern with identifier BB, identifier BB and the stroke amount YY of the segment cylinders corresponding to the second segment foot 22B and the third segment foot 22C are stored in association. In this way, the relationship between the pattern and the target stroke amount of each segment cylinder is stored in advance. Based on this, the control device 30 may determine the target stroke amount of each segment cylinder based on the stored relationship and the pattern to be used. Regarding the pattern to be used, the operator may input the identifier into the control device 30 when the pattern is changed, or the control device 30 may identify the RFID (Radio Frequency Identification) tag provided on the pattern.

[0029] Figures 6(A) to 6(D) illustrate an example of the relationship between the pattern shape and the height of the segment feet. As shown in Figure 6(A), assume that the first pattern 16 is delivered when each segment foot is in its original position. Here, to express the shape (height) of the first pattern 16, a position on the left in the figure is used as the reference point (i.e., "0"), and a position protruding upwards is considered positive, while a position protruding downwards is considered negative. In this case, the shape of the first pattern 16 is as follows: height "0" at the position corresponding to the first segment foot 22A, height "2" at the position corresponding to the second segment foot 22B, height "1" at the position corresponding to the third segment foot 22C, height "4" at the position corresponding to the fourth segment foot 22D, height "-2" at the position corresponding to the fifth segment foot 22E, and height "0" at the position corresponding to the sixth segment foot 22F.

[0030] Once the pattern shape is acquired, the segment feet are moved before sand filling to ensure that the sand is evenly distributed throughout the molding space, as shown in Figure 6(B). Figure 6(B) shows the state after the segment feet have been moved and the sand has been filled. For example, the tip of the second segment foot 22B is made to protrude downwards by a height of "2". Similarly, the tip of the third segment foot 22C is made to protrude downwards by a height of "2". The tip of the fourth segment foot 22D is made to protrude downwards by a height of "4". The first segment foot 22A, the fifth segment foot 22E, and the sixth segment foot 22F are maintained in their original positions. This adjusts the amount of sand filled into the metal frame 10 and the molding frame 19 to correspond to the shape of the first pattern 16.

[0031] Next, as shown in Figure 6(C), the segment feet are moved after sand filling but before squeezing. For example, the tip of the second segment foot 22B, which is protruding by a height of "2" in Figure 6(B), is retracted by a height of "2" to return it to its original position. Similarly, the tip of the fourth segment foot 22D, which is protruding by a height of "4", is retracted by a height of "4" to return it to its original position. Then, the tip of the fifth segment foot 22E is made to protrude so that it is positioned 4" lower. The area corresponding to the fifth segment foot 22E tends to have a larger amount of sand sandwiched between the upper squeeze plate 20 and the first pattern 16 because the distance from the upper squeeze plate 20 to the first pattern 16 is long. By making the fifth segment foot 22E protrude, the area with a larger amount of sand can be compressed more strongly than other areas. In this way, the framed molding machine 1 can perform sand filling corresponding to the pattern shape, so the sand thickness inside the metal frame 10 and the molding frame 19 can be made uniform.

[0032] Next, a squeeze is performed. As shown in Figure 6(D), the squeeze pressure pushes the tip of the third segment foot 22C and the tip of the fifth segment foot 22E upward. The movement of the segment feet due to the squeeze pressure allows the framed molding machine 1 to avoid damaging the mold.

[0033] [Summary of Embodiments] In the framed molding machine 1, a segment cylinder is provided in each segment foot. The stroke amount of each segment cylinder can be adjusted steplessly. Therefore, the framed molding machine 1 can make the sand thickness (height) in the metal frame 10 and the molding frame 19 more uniform compared to cases where the stroke amount is adjusted in a few steps. Thus, the framed molding machine 1 can suppress variations in mold strength.

[0034] [Variations] Although various exemplary embodiments have been described above, the invention is not limited to the exemplary embodiments described above, and various omissions, substitutions, and modifications may be made. For example, although an example in which the displacement sensor is a laser displacement meter has been described, the displacement may also be measured using an encoder or the like.

[0035] [Summary of Embodiments of the Disclosure] The Disclosure includes the following embodiments: (Clause 1) A framed molding machine according to one aspect of the Disclosure comprises: a squeeze plate having a main surface defining a molding space, the main surface having a plurality of openings; a plurality of segment feet arranged in the plurality of openings, each segment foot being movable from the main surface of the squeeze plate toward the molding space; and a plurality of segment cylinders corresponding to the plurality of segment feet, each segment cylinder being connected to each segment foot and having a stepless adjustment of stroke amount.

[0036] In this framed molding machine, a segment cylinder is provided in each segment foot. The stroke amount of each segment cylinder can be adjusted steplessly. Therefore, compared to a molding machine where the stroke amount is adjusted in a few steps, the framed molding machine can achieve a more uniform sand thickness (height) within the metal frame and the mold. Thus, the framed molding machine can reduce variations in mold strength.

[0037] (Clause 2) The framed molding machine described in Clause 1 may further include a plurality of displacement sensors for detecting the stroke amount of a plurality of segment cylinders, and a control device connected to the plurality of segment cylinders and the plurality of displacement sensors, which adjusts the stroke amount of each segment cylinder so that the stroke amount detected by each displacement sensor approaches the target value of each segment cylinder. In this case, the framed molding machine can adjust the stroke amount of the segment cylinders to the target value based on the detection results of the displacement sensors.

[0038] (Clause 3) In the framed molding machine described in Clause 2, the control device may have a memory unit that stores the relationship between the pattern defining the molding space and the target value of the stroke amount of each segment cylinder, and may determine the target value of the stroke amount of each segment cylinder based on the relationship stored in the memory unit and the pattern to be used. In this case, the control device of the framed molding machine can determine the target value of the stroke amount of each segment cylinder once the pattern to be used is determined, thus contributing to automation. (Clause 4) In the framed molding machine described in Clause 2 or 3, each displacement sensor may be a laser displacement meter.

[0039] 1... Molding machine with frame, 10... Metal frame, 20... Upper squeeze plate (an example of a squeeze plate), 22... Multiple segment feet, 26... Multiple segment cylinders, 27... Multiple displacement sensors, 30... Control device.

Claims

1. A molded molding machine with a frame, comprising: a squeeze plate having a main surface that defines a molding space, the main surface having a plurality of openings; a plurality of segment feet arranged in the plurality of openings, each segment foot being movable from the main surface of the squeeze plate toward the molding space; and a plurality of segment cylinders corresponding to the plurality of segment feet, each segment cylinder being connected to each segment foot and having a stepless adjustment of stroke amount.

2. The framed molding machine according to claim 1, further comprising: a plurality of displacement sensors for detecting the stroke amount of the plurality of segment cylinders; and a control device connected to the plurality of segment cylinders and the plurality of displacement sensors, which adjusts the stroke amount of each segment cylinder so that the stroke amount detected by each displacement sensor approaches the target value of each segment cylinder.

3. The control device has a storage unit that stores a relationship between a pattern defining the molding space and a target value for the stroke amount of each segment cylinder, and determines a target value for the stroke amount of each segment cylinder based on the relationship stored in the storage unit and the pattern to be used, the framed molding machine according to claim 2.

4. The framed molding machine according to claim 2 or 3, wherein each displacement sensor is a laser displacement meter.

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