Casting Machine Mold Tilting and Robot Crucible Control
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Solution Overview
Problem
Existing casting machines face challenges in ensuring complete filling of casting molds without air pockets or contamination, requiring high melt temperatures and precise crucible positioning, which increases costs and reduces product quality.
Innovation Solution
A casting machine with a pivoting device and sensor system that tilts the mold during pouring, allowing the robot to move the crucible in sync with the mold's movement, eliminating the need for high temperatures and precise positioning, and enabling precise control of melt flow based on mold shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the crucible is directly positioned at the sprue using a robot, then the melt transfer is simplified, but the positioning precision becomes difficult to achieve
Solution Approach 1:
A sensor device is introduced as an intermediary between the robot and the casting mold. The sensor detects the position and orientation of the mold, and this information is used to control the robot's movement, enabling the crucible to be precisely positioned at the sprue without requiring direct complex coordination
2Manufacturing precision
If the casting mold is tilted during filling, then complete filling without air pockets is achieved, but the coordination complexity between crucible and mold increases
Solution Approach 1:
The sensor device provides real-time feedback on the casting mold's position and orientation during tilting. This feedback is used to dynamically adjust the robot's crucible positioning, maintaining precise alignment between the crucible and sprue even as the mold tilts, thereby simplifying the overall coordination requirement
Solution Approach 2:
The sensor device acts as an intermediary that mediates between the tilting mold and the robot-controlled crucible. By detecting mold movement and translating it into corresponding robot positioning commands, the sensor simplifies the coordination complexity between these two moving components
3Manufacturing precision
If the melt is transferred by robot to casting mold, then positioning is achieved, but temperature loss and oxide formation increase
Solution Approach 1:
The sensor device serves as an intermediary that enables precise positioning of the crucible at the sprue, eliminating the need for intermediate transfer steps. This direct positioning approach maintains melt temperature and prevents oxide formation by avoiding additional exposure to air and turbulence
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method ensures complete and smooth filling of molds, reduces oxide formation, and enhances product quality by maintaining melt temperature and preventing turbulence, thus making the casting process more cost-effective.
Implementation Method 1
the movement of the casting mold is detected by means of a sensor device of the casting machine during the filling of the melt into the casting mold
Implementation Method 2
the crucible is moved by means of the robot as a function of the movements of the casting mold
Implementation Method 3
the casting mold is moved and tilted about an axis by means of a pivoting device of the casting machine during the filling of the melt into the casting mold
Implementation Method 4
liquid metal is always poured into a casting mold until the casting mold or a cavity of the casting mold is completely filled
Data Source
Figure 1~4
Figure 5a~5e
Figure 6a~6e
AI summary
The invention relates to a casting machine and a method for casting a melt into a mold, wherein at least one mold (24) is mounted on a frame of a casting machine, wherein a melt (34) is poured into the mold by means of a crucible (25) of the casting machine, wherein the mold is moved and tilted about an axis (32) by means of a swiveling device of the casting machine during the pouring of the melt into the mold, wherein the crucible is moved by means of a robot of the casting machine during the pouring of the melt into the mold, wherein the movement of the mold during the pouring of the melt into the mold is detected by means of a sensor device of the casting machine, wherein the crucible is moved by means of the robot depending on the movement of the mold.