Flask Removal Unit for Sand Molding Cycle Optimization
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Solution Overview
Problem
Existing molding apparatuses have a long cycle time for flask removal, which hinders productivity improvements.
Innovation Solution
A flask removal unit that includes an upper and lower flask, a guide member, a flask moving unit, an extrusion unit, a support unit, and a control unit, which allows for the efficient removal of a cope and drag from the flasks by moving the flasks to a position where a pattern member can be disposed between them during the mold conveyance process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the molding apparatus repeats the cycle of extruding cope and drag, separating flasks, clamping match plate, filling sand, and squeezing, then the molding process can be completed, but the cycle time becomes long and productivity is reduced
Solution Approach 1:
The flask moving unit moves the upper and lower flasks to the pattern disposal position in advance, before the mold is fully conveyed to the unloading position. This preliminary positioning enables the pattern member to be disposed between the flasks without waiting for the complete conveyance cycle, thereby overlapping operations and reducing the overall cycle time while maintaining continuous production flow
Solution Approach 2:
The control unit coordinates the flask moving unit and support unit to operate simultaneously during the mold conveyance period. The flasks are moved and positioned while the mold is being conveyed, ensuring that no time is wasted in between operations. This continuous overlapping of useful actions eliminates idle time and maintains constant productive activity throughout the cycle
2Loss of time
If the flask moving unit moves the flasks to the pattern disposal position during mold conveyance, then the cycle time is shortened, but the device complexity increases
Solution Approach 1:
The flask moving unit is designed to perform multiple functions: it moves the flasks along the guide member for positioning, and can also adjust the flasks to the appropriate separation distance for pattern disposal. The support unit similarly serves both to convey the mold and to position it for unloading. This multi-functionality reduces the need for separate dedicated mechanisms, thereby limiting the increase in device complexity while achieving cycle time reduction
Data Source
AI summary
Provided is a flask removal unit that removes a cope and a drag from an upper and lower flask. The flask removal unit includes a guide member, a flask moving unit, an extrusion unit, a support unit configured to move a support member together with an extrusion member to support the mold extruded from the upper and lower flask by the extrusion unit, and configured to convey the mold to an unloading position where the mold is unloaded, and a control unit. The control unit is configured to perform control such that at least one of an upper flask and an lower flask is moved to a position where the pattern member is able to be disposed between the upper flask and the lower flask in a period in which the support unit conveys the mold to the unloading position.