Core Sand Filling Method for Under-Blow Molding
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Solution Overview
Problem
The under-blow type core molding machine faces challenges in efficiently filling the core box with core sand due to issues with air supply, leading to low packing density and surface wrinkles in manufactured cores.
Innovation Solution
A core sand filling method that involves supplying aeration air to float and fluidize the core sand in the blow head, followed by controlled compressed air injection into the sand storage chamber to fill the core box cavity, with pressure sensors and a control unit managing the air supply to ensure complete filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If under-blow type core molding machine is used to reduce machine height, then machine profile is reduced, but core box filling quality deteriorates
Solution Approach 1:
The invention applies preliminary action by first supplying aeration air to the blow head to float and fluidize the core sand before introducing compressed air for filling. This pre-fluidization ensures the sand is in optimal state for subsequent high-speed filling, preventing defects like low packing density and surface wrinkles that occur when compressed air is supplied alone.
Solution Approach 2:
The invention maintains continuity of useful action by overlapping the aeration air supply period with the compressed air supply period. The aeration air continues to be supplied during the compressed air filling process, ensuring continuous fluidization of sand throughout the filling operation, which prevents filling defects and ensures high-quality core production.
2Productivity
If compressed air is supplied to blow head to fill core box quickly, then filling speed increases, but sand fluidization is insufficient causing defects
Solution Approach 1:
The invention segments the air supply function into two distinct systems: aeration air supply for sand fluidization and compressed air supply for filling propulsion. This segmentation allows each system to perform its specific function optimally - aeration air creates and maintains sand fluidization, while compressed air provides the driving force for rapid filling, eliminating the trade-off between speed and quality.
Solution Approach 2:
The invention uses aeration air as an intermediary that mediates between the compressed air and the core sand. The aeration air creates a fluidized state in the sand, acting as an intermediate phase that allows compressed air to efficiently propel sand into the core box without causing defects. This intermediary aeration layer ensures smooth sand flow and prevents filling defects.
3Manufacturing precision
If aeration air is supplied to float sand, then sand fluidization improves, but filling time increases
Solution Approach 1:
The invention applies dynamics by adjusting the supply amounts and timing of both aeration air and compressed air during the filling process. The control unit dynamically controls the aeration air supply amount to maintain optimal sand fluidization, while simultaneously controlling compressed air supply to ensure rapid filling. This dynamic control prevents both over-fluidization (which would waste time) and under-fluidization (which would cause defects).
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 effectively fills the core box with core sand, improving manufacturing efficiency by ensuring full floating and fluidization of the sand, thereby reducing defects and enhancing core quality.
Implementation Method 1
supplying an aeration air into the sand blow chamber by aeration air supply means so as to float and fluidize the core sand within the sand blow chamber
Implementation Method 2
supplying a compressed air into the sand storage chamber by compressed air supply means so as to fill the cavity of the core box with the floated and fluidized core sand from within the sand blow chamber
Data Source
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AI summary
When employing an under-blow scheme for blowing core sand into a core box located on the upper side, a core sand filling method which can favorably fill the core box with core sand, thereby contributing to improving the efficiency in manufacturing cores, is provided. The core sand filling method comprises a step of operating an aeration air supply means 9A, so as to float and fluidize core sand within a sand blow chamber 4 and, when a pressure Pf of the sand blow chamber 4 measured by the first pressure sensor 14 reaches a first pressure P1, operating a compressed air supply means 7A and a step of stopping the aeration air supply means 9A and compressed air supply means 7A from operating when each of the pressure Pf within the sand blow chamber 4 and a pressure Pc within a sand storage chamber 5 is a second pressure P2 or higher while a differential pressure ΔP = Pc - Pf is a third pressure P3 or lower.