Core Forming Device Piston Position Feedback Control
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Solution Overview
Problem
The core forming device experiences variability in the position of the piston upon completion of injection, leading to inconsistent core mass and strength due to material leakage and other factors, resulting in dispersed quality of the formed cores.
Innovation Solution
A core forming device equipped with a kneading tank, raw material supply unit, mold, piston, position sensor, and control unit that adjusts the raw material supply based on the detected piston position relative to a reference position, ensuring consistent core formation by calculating the actual amount of material injected each time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the same mass of raw materials is supplied every time injection is carried out, then the production process is simple and efficient, but the position of the piston upon completion of injection disperses, leading to dispersed core quality
Solution Approach 1:
The system uses a position sensor to detect the piston position upon completion of injection and feeds this information back to the control unit. The control unit then adjusts the raw material supply amount for the next injection based on the detected position deviation from the reference, creating a closed-loop feedback control system that maintains consistent core quality.
Solution Approach 2:
The system dynamically changes the supply amount parameter of raw materials based on the detected piston position. When the piston position deviates from the reference position, the control unit modifies the supply amount to compensate for the deviation, ensuring that the core quality remains consistent despite variations in injection conditions.
2Ease of operation
If the piston position is allowed to vary, then the device operation is flexible and simple, but the core mass and strength become inconsistent
Solution Approach 1:
The position sensor continuously monitors the piston position and provides feedback to the control unit. This feedback mechanism allows the system to automatically adjust the raw material supply to maintain consistent core strength without requiring manual intervention or complex operational procedures.
Solution Approach 2:
The system performs self-adjustment by automatically modifying the raw material supply amount based on the detected piston position. The control unit calculates the required supply amount using the position information and executes the adjustment without external control, enabling the system to maintain consistent core quality autonomously.
3Manufacturing precision
If a position sensor and control unit are added to monitor and adjust piston position, then core quality consistency is improved, but the device complexity increases
Solution Approach 1:
The system implements a feedback control mechanism using a position sensor and control unit. The position sensor detects the piston position, and the control unit adjusts the raw material supply based on the detected position, creating a relatively simple feedback loop that effectively maintains core quality consistency without requiring complex multi-component systems.
Data Source
AI summary
A core forming device is equipped with a kneading tank in which raw materials of a core are kneaded, a raw material supply unit that supplies the raw materials to the kneading tank, a mold that accommodates a kneaded material including the raw materials kneaded in the kneading tank and that forms the core, a piston that injects the kneaded material into the mold, a position sensor that detects a position of the piston, and a control unit that controls a supply amount of the raw materials supplied to the kneading tank from the raw material supply unit. The control unit determines the supply amount of the raw materials based on a difference between the position of the piston upon completion of injection and a reference position of the piston.