Core Sand Feed Humidification to Prevent Mixture Crusting
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Solution Overview
Problem
Premature drying and crusting of the mixture during the mixing process leads to contamination and clogging of the mixing and feeding equipment, resulting in production stoppages and increased cleaning intervals.
Innovation Solution
Moistening the non-mixing areas of the mixing and feeding devices using an ultrasonic atomizer to generate a suspended aerosol, maintaining a high humidity level to prevent moisture evaporation and mixture hardening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mixture is kept in the mixing device and feeding device during production, then the mixture can be continuously supplied to the mold making device, but moisture evaporates from the mixture causing it to dry out and crust over
Solution Approach 1:
The patent applies the principle of creating a humidified atmosphere within the mixing device and feeding device to prevent moisture evaporation. By introducing water vapor or moisture into the air within these devices, an inert-like environment is created that prevents the binder mixture from drying out and crusting, thereby enabling continuous production without compromising mixture quality
Solution Approach 2:
The patent introduces humidified air or water vapor as an intermediary substance between the mixture and the surrounding environment. This intermediary layer prevents direct moisture evaporation from the mixture surfaces exposed in the mixing and feeding devices, allowing continuous operation while maintaining mixture moisture content
2Reliability
If cleaning intervals are shortened to prevent contamination, then equipment reliability is maintained, but production time is lost and productivity decreases
Solution Approach 1:
The patent applies preliminary action by maintaining humidity in the mixing and feeding devices during operation, which prevents crusting and contamination before they can occur. This proactive approach eliminates the need for frequent cleaning interruptions, thereby maintaining both equipment reliability and production continuity
3Object-affected harmful factors
If cooling is applied to prevent drying, then mixture moisture is preserved, but additional energy consumption and equipment complexity increase
Solution Approach 1:
The patent changes the environmental parameter (humidity) within the mixing and feeding devices rather than changing the temperature of the mixture. By controlling the humidity level in the surrounding air, the invention prevents moisture evaporation without requiring cooling systems, thus avoiding increased device complexity and energy consumption
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
Prevents mixture drying and crusting, reducing contamination and extending cleaning intervals, thereby enhancing productivity and quality in mold and core production.
Implementation Method 1
the liquid used for moistening is atomized into a suspended aerosol by at least one ultrasonic atomizer and is supplied to the mixing device and/or the feeding device and/or the sand storage unit
Implementation Method 2
the suspended aerosol contains such small liquid particles that they evaporate directly, increasing the humidity without condensing or forming condensate
Data Source
Figure 1
AI summary
To produce molds or cores for foundry purposes from a mixture (M) of molding material or sand and at least one binder, the mixture (M) is mixed by means of a mixing device (20) and fed by means of a feeding device (30) to at least one sand storage unit (40) of a core or mold making device (50), wherein the mixing-free area (21) of the mixing device (20) is moistened or kept moist at least temporarily and/or the feeding device (30) located between the mixing device (20) and the core or mold making device (50) and/or the sand storage unit (40) behind the feeding device (30) and in front of the core or mold making device (50) is moistened or kept moist by means of a liquid (71).wherein the liquid (71) used for moistening is atomized into a suspended aerosol by at least one ultrasonic atomizer (60) and is supplied to the mixing device (20) and/or the feeding device (30) and/or the sand storage unit (40) via pipelines (81, 82, 83).