Cope and Drag Flask Shift Measurement for Casting Defect Prevention
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Solution Overview
Problem
Shifts in cavity parts during the molding process can lead to defects in cast products, as existing methods to prevent such shifts are inadequate, particularly due to wear in pins and bushings used for alignment, which may not be uniformly worn and can result in unpredictable shifts.
Innovation Solution
A method that measures shifts between carrier plates and flasks, uses positioning jigs to align flasks and carrier plates, and monitors the degree of wear of these jigs to prevent shifts within an allowable range, generating alarms for excessive wear and facilitating timely maintenance and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pins and bushings are provided to prevent shift between carrier plate and flask, then alignment precision is improved, but reliability deteriorates due to wear and unpredictable shift
Solution Approach 1:
The patent implements a feedback mechanism by measuring the actual shift between carrier plate and flask using sensors, comparing it against allowable limits, and triggering alarms or stopping the molding process when limits are exceeded. This closed-loop monitoring system addresses the unreliability of passive mechanical restraints by actively detecting and responding to wear-induced misalignment.
Solution Approach 2:
The patent replaces the purely mechanical pin-bushing alignment system with a hybrid system that incorporates sensors, control units, and alarm mechanisms. This substitution of mechanical restraint with sensor-based detection and control enables more reliable shift prevention by continuously monitoring actual positions rather than relying solely on wear-prone mechanical components.
2Ease of operation
If pin and bushing are used for positioning, then ease of operation is improved, but manufacturing precision deteriorates due to non-uniform wear
Solution Approach 1:
The sensor-based measurement system provides feedback on actual shift conditions, enabling the system to compensate for non-uniform wear effects. By continuously monitoring position deviations and comparing them against allowable limits, the system maintains manufacturing precision even when mechanical positioning components exhibit irregular wear patterns.
Data Source
AI summary
A method is provided for measuring a shift between a carrier for a pattern (a carrier plate) and a flask and preventing a defect caused by a shift in the cavity parts. The method for preventing a defect caused by the shift in the cavity parts in molding a cope and a drag with flasks by using a cope flask (110) that is assembled with a carrier plate (130) for the cope flask and a drag flask (120) that is assembled with a carrier plate (140) for the drag flask, comprises the steps of measuring a shift between the carrier plate (130) for the cope flask and the cope flask (110), measuring a shift between the carrier plate (140) for the drag flask and the drag flask (120), measuring a shift between the cope flask (110) and the drag flask (120) that have been assembled, determining if a shift in cavity parts is within an allowable range, wherein the data on the shift is obtained based on the shift between the carrier plate (130) for the cope flask and the cope flask (110), the shift between the carrier plate (140) for the drag flask and the drag flask (120), and the shift between the cope flask (110) and the drag flask (120, that have been assembled.