Detachable Feeder Elements for Metal Casting Moulds
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Solution Overview
Problem
Vertical parting surface metal casting processes face limitations in shaping complexity and productivity, with excessive energy consumption and increased complexity in removing non-productive parts, particularly due to the need for multiple feeding sleeves which complicate the casting process and increase energy expenditure.
Innovation Solution
The integration of feeder elements that can be attached to the second mould pattern when the swing plate is pivoted to the sidestep position, allowing for controlled solidification and reduced energy consumption by optimizing the design and automation of the mould preparation process, enabling more efficient use of mould space and reducing the risk of casting defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple feeding sleeves are used to control solidification and prevent shrinkage voids, then casting quality is improved, but device complexity and energy consumption increase
Solution Approach 1:
The invention extracts the feeding function from traditional feeding sleeves and relocates it to a separate feeder element that can be attached to the mould pattern. This allows the feeding function to be removed from the main mould structure, reducing mould complexity while maintaining the ability to control solidification and prevent shrinkage voids through properly designed feeder elements.
Solution Approach 2:
The invention segments the feeding function from the mould structure by using separate, detachable feeder elements. Instead of having multiple feeding sleeves integrated into the mould, the feeding function is divided into independent feeder components that can be selectively attached and positioned, thereby reducing overall device complexity while maintaining casting quality.
2Reliability
If multiple feeding sleeves are used to control solidification, then casting quality is improved, but energy consumption increases
Solution Approach 1:
By extracting the feeding function from the mould structure and implementing it through separate feeder elements, the invention reduces the thermal mass that needs to be heated and maintained. This separation allows for more efficient heat utilization and reduced energy consumption while still achieving proper solidification control and casting quality.
3Productivity
If feeder elements are attached during the swing plate pivoting process, then mould preparation efficiency is improved, but device complexity increases
Solution Approach 1:
The invention merges the feeder element attachment operation with the existing swing plate pivoting motion. By combining these two operations into a single coordinated movement, the system improves mould preparation efficiency without requiring entirely separate mechanisms, thus limiting the increase in device complexity.
Solution Approach 2:
The swing plate mechanism is given multiple functions: it not only positions the mould pattern but also facilitates feeder element attachment during its pivoting motion. This multi-functionality improves productivity by consolidating operations into existing movements rather than adding dedicated separate mechanisms.
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 enhances the freedom of designing complex shapes, reduces the risk of casting defects, and improves mould yield and energy efficiency by allowing for more efficient use of mould space and automation levels, from fully automated to manual, thereby increasing productivity and quality.
Implementation Method 1
the swing plate is configured to be translatorily movable in a horizontal direction to a released position and further to be pivotable upwardly to a sidestep position
Implementation Method 2
a swing plate carrying a second mould pattern, the swing plate is configured to be translatorily movable in a horizontal direction to a released position and further to be pivotable upwardly to a sidestep position
Implementation Method 3
the supplied mould sand is rammed up or compressed to form the mould block
Implementation Method 4
the mould block is pushed out of the ram-up machine by horizontally movable piston operating the squeeze plate carrying a first mould pattern
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
An arrangement and method in a ram-up machine (1) for moulds (2) for metal casting (10) comprising: - a squeeze plate (3) carrying a first mould pattern (32) - a horizontally movable piston (31) for operating the squeeze plate (3) and a finished mould block (2), - a sand supply system (7) - a swing plate (4) carrying a second mould pattern (42), the swing plate (4) is configured to be translatorily movable in a horizontal direction to a released position (4r) and further to be pivotable upwardly to a sidestep position (4s), - a feeder element insertion configuration (50) wherein one or plurality of feeder elements (5) are configured to be attached to the second mould pattern (42) when during operation the swing plate (4) carrying the second mould pattern (42) is pivoted to the sidestep position (4s).