Permanent Mold Casting Machine Upper Mold Stabilization
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Solution Overview
Problem
Conventional permanent mold casting machines face issues with the upper mold sliding horizontally during opening, leading to potential damage of casting products and increased costs due to high-capacity hydraulic cylinders required for lifting and lowering, especially when dealing with complex product cavities.
Innovation Solution
A mold clamping mechanism attached to the lifting and lowering frame, utilizing a circular fastening member and guide rod to stabilize the upper mold's separation from the lower mold, allowing for stable opening and reducing the need for high-capacity actuators by using an electric motor for lifting and lowering operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the upper mold base is lifted and lowered alone to separate and contact the upper mold with the lower mold, then the mold opening and closing operations can be performed, but the supporting frames become very high and are apt to bend under large loads, causing the upper mold to slide horizontally and potentially damage the casting product
Solution Approach 1:
The invention divides the mold handling function into two separate mechanisms: the lifting and lowering frame for vertical movement, and the mold clamping mechanism for horizontal positioning and clamping. This segmentation allows each mechanism to perform its specific function without compromising the other, preventing horizontal sliding while maintaining operational capability
Solution Approach 2:
The mold clamping mechanism acts as an intermediary between the lifting and lowering frame and the molds. It provides the necessary clamping force to prevent horizontal sliding during mold separation and contact operations, while being driven by a smaller actuator rather than requiring the lifting frame to provide both vertical and horizontal control
2Ease of operation
If the upper mold base travels a long distance when lifted or lowered, then the mold opening and closing can be achieved, but the supporting frames must be very high and require high-capacity hydraulic cylinders, increasing machine size and cost
Solution Approach 1:
The invention separates the functions of mold separation/contact and mold clamping into different mechanisms. The lifting and lowering frame handles only vertical movement with a compact design, while the mold clamping mechanism handles the clamping function, allowing the supporting frames to be shorter and eliminating the need for high-capacity hydraulic cylinders
3Reliability
If a high-capacity actuator is used for mold opening to prevent horizontal sliding, then the upper mold position stability is improved, but the machine size increases and operational speed decreases
Solution Approach 1:
The invention divides the actuation functions between two mechanisms: the lifting and lowering frame with its actuator for vertical movement, and the mold clamping mechanism with its own actuator for clamping. This allows the mold clamping actuator to be smaller and faster since it only needs to provide clamping force, not move the entire mold assembly, thereby improving operational speed while maintaining position stability
Solution Approach 2:
The invention replaces the need for a large, slow actuator that would be required to simultaneously control vertical movement and horizontal clamping with two separate, smaller actuators. This substitution of the mechanical actuation system enables faster response times and higher operational speed while maintaining the necessary position stability
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 solution enables stable opening of the upper mold, minimizes machine size, and allows for higher operational speed while reducing energy consumption and the need for large servomotors, as the upper mold lifting and lowering mechanism only requires power for lifting and lowering, not mold opening.
Implementation Method 1
the circular fastening member of the guide rod being engaged by means of a fastening mechanism
Implementation Method 2
if the process of lifting and lowering or opening and closing the upper mold is carried out by an electric motor
Data Source
AI summary
The present invention provides a method to operate an upper mold in a permanent mold casting machine and the permanent mold casting machine used for the method where a stable operation of the upper mold is realized. The method to operate the upper mold against a lower mold whereby molten metal held in a holding furnace is poured via a stoke into s set of molds consisting of the upper and lower molds and to manufacture casting products, the mold casting machine comprising a mold clamping mechanism attached to a lifting and lowering frame, wherein the mold clamping mechanism is equipped with the upper mold lifting and lowering means that carries out the assembling and separation of the upper and lower molds by lifting and lowering, relative to the lower mold and the lifting and lowering frame, the upper mold being attached to the lower part of the upper mold lifting and lowering means, wherein the space for a setting of a core and for taking out the products is formed between the upper and lower molds by the lifting of the upper mold lifting and lowering means relative to the lifting and lowering frame, and by the lifting of the lifting and lowering frame relative to the lower mold, and wherein the molten metal is poured, while the lifting and lowering frame, to which the mold clamping mechanism having the upper mold is attached, is kept fixed relative to the lower mold, and then the permanent mold casting machine causes the upper mold to be separated from the lower mold by the operation of the upper mold lifting and lowering means, while keeping the lifting and lowering frame fixed relative to the lower mold.