Flask Mating Misalignment Detection Using Force Sensors
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Solution Overview
Problem
Existing methods for automatic flask mating in molding processes fail to prevent misalignment and wear-related issues, leading to casting defects, mold damage, and increased operational workload due to friction and sand dust particles.
Innovation Solution
Incorporation of a physical quantity detection sensor into the automatic flask mating device to detect the fitting and combining forces between pins and bushings, allowing for real-time computation and determination of proper alignment and force levels, thereby preventing misalignment and mold damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pins and bushings are finished to high hardness by quenching to reduce wear, then wear resistance is improved, but friction from repeated fittings and sand dust particles still causes wear and misalignment
Solution Approach 1:
The patent applies preliminary action by detecting the fitting force between pins and bushings before completing the flask mating process. The detection device measures the force during insertion, and the control unit compares it against predetermined thresholds to identify wear or misalignment issues before they cause casting defects, allowing preventive action to be taken
Solution Approach 2:
The patent implements feedback by using a detection device that continuously monitors the fitting force between pins and bushings during flask mating. The control unit receives this feedback, compares it with predetermined ranges, and can issue warnings or stop the process when abnormal wear or misalignment is detected, creating a closed-loop control system
2Measurement precision
If operators separate cope and drag flasks immediately after flask mating to visually check for mold or core damage, then detection accuracy is improved, but cycle time increases and operator workload increases
Solution Approach 1:
The patent applies self-service by enabling the system to automatically detect and determine whether molds or cores are damaged during the flask mating process itself. The detection device measures forces between the cope and drag, and the control unit automatically interprets these measurements to identify interference or damage without requiring operator intervention or separation of flasks
Solution Approach 2:
The patent replaces the manual visual inspection method with an automated detection system that uses force sensors and control algorithms. Instead of operators physically separating and examining molds, the mechanical detection device continuously monitors forces during mating, substituting automated sensing and computational analysis for human visual inspection
3Manufacturing precision
If pins and bushings are used for positioning to prevent misalignment, then manufacturing precision is improved, but friction and wear from repeated use cause misalignment and casting defects
Solution Approach 1:
The patent applies preliminary action by detecting the fitting force between pins and bushings before completing the flask mating process. The detection device measures the force during insertion, and the control unit compares it against predetermined thresholds to identify wear or misalignment issues before they cause casting defects, allowing preventive action to be taken
Solution Approach 2:
The patent implements feedback by using a detection device that continuously monitors the fitting force between pins and bushings during flask mating. The control unit receives this feedback, compares it with predetermined ranges, and can issue warnings or stop the process when abnormal wear or misalignment is detected, creating a closed-loop control system
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
Enables immediate and automatic detection of misalignment and mold damage, reducing casting defects and operational inefficiencies by ensuring accurate flask mating and allowing for predictive maintenance of worn components.
Implementation Method 1
a force generated by the fitting together of pins and bushings provided on the cope molding flask and the drag molding flask is detected by means of a physical quantity detection sensor capable of detecting the force
Implementation Method 2
a force generated by the combining of the cope and the drag is detected by means of a physical quantity detection sensor capable of detecting the force
Data Source
AI summary
[Problem] To provide a method and device that automatically detects misalignment during flask mating in an automatic flask mating device for molding flasks for casting.[Solution] In an automatic flask mating device, an external force applied to a cope with a cope molding flask M1 during flask mating is detected by means of a physical quantity detection sensor 60, quantified by a computation/storage/determination processing device 61, and then compared with a numerical value at a normal time for determination to thereby determine whether the flask mating has normally completed and detect flask mating misalignment. A force sensor is preferably used as the physical quantity detection sensor.