Core Molding Supply Calculation Using Molded-Core Density
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Solution Overview
Problem
The density of core sand before and after injection can vary, leading to fluctuations in the piston position and deteriorating the accuracy of raw material supply calculation for core molding.
Innovation Solution
A core molding apparatus and method that calculates the amount of raw material supply by subtracting the remaining kneaded material volume in the kneading tank after injection from a total reference volume, using the density of the molded core and adjusting for changes in volume through the injection plate and mold volumes, and detecting piston position to improve accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the calculation uses the density of core sand before injection and piston position difference, then the calculation method is simple, but the calculation accuracy deteriorates due to density changes during injection
Solution Approach 1:
The patent changes the density parameter from the pre-injection sand density to the post-injection molded core density. This parameter change resolves the contradiction by using the final state density (which reflects the actual compacted state) to calculate the raw material supply, thereby improving accuracy without significantly increasing calculation complexity
Solution Approach 2:
The patent implements a feedback mechanism where the actual piston position after injection is detected and used to calculate the remaining kneaded material volume. This feedback loop allows the system to account for actual density changes and piston position deviations, improving calculation accuracy while maintaining reasonable system complexity
2Productivity
If the piston position is used to calculate raw material supply, then the calculation can be performed, but the piston position fluctuates widely due to density changes causing calculation inaccuracy
Solution Approach 1:
The patent introduces the molded core density as an intermediary parameter between the piston position and the raw material supply calculation. Instead of directly using the piston position (which fluctuates due to density changes), the system uses the molded core density to bridge the gap, providing a stable basis for calculation while maintaining productivity
Solution Approach 2:
The patent performs preliminary calculation of the total reference volume of kneaded material and uses the density of the molded core (obtained from actual measurement or predetermined values) to calculate the raw material supply. This preliminary action approach allows the system to prepare calculation parameters in advance while accounting for density changes, maintaining both productivity and precision
Data Source
AI summary
A core molding apparatus and a core molding method capable of reducing the possibility of the deterioration in the calculation accuracy of the amount of supply of a raw material for a core are provided. A core molding apparatus includes: a kneading tank configured to knead a raw material for a core; a raw material supply unit configured to supply the raw material to the kneading tank; a mold configured to contain a kneaded material made of the raw material kneaded in the kneading tank and to mold the core; a piston configured to inject the kneaded material contained in the kneading tank into the mold; and a control unit configured to control an amount of supply of the raw material from the raw material supply unit to the kneading tank.