Flaskless Moulding Machine Indexing with Segmented Conveyor
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Solution Overview
Problem
The increasing production rate of moulds in metal foundries leads to a heavier mould string, which requires more power and force for indexing, potentially damaging the moulds and causing misalignment, and existing equipment may not be strong enough to handle the increased weight and precision needed.
Innovation Solution
The method involves the flaskless moulding machine assisting the mould conveyor in advancing the mould string for the first part of the distance, reducing the strength and travel requirements of the mould conveyor, allowing for a higher production rate while maintaining precision and alignment, and enabling the use of existing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production rate of moulds is increased, then the output of the flaskless moulding machine is improved, but the weight of the mould string increases requiring more power and force for indexing
Solution Approach 1:
The indexing process is segmented into two phases: the pressure plate performs initial indexing by pushing the mould string a first distance, then the mould conveyor completes the indexing by pushing the mould string a second distance. This segmentation distributes the force requirements across different components and time periods, allowing the pressure plate to handle the heavier initial load when the mould string is shorter, while the mould conveyor handles the remaining distance with reduced force requirements.
Solution Approach 2:
The pressure plate performs preliminary indexing action by advancing the mould string a first distance before the mould conveyor takes over. This preliminary action reduces the remaining distance that the mould conveyor must travel, thereby reducing the force and power requirements for the mould conveyor while still achieving the complete indexing function.
2Force
If stronger mould conveyors are used to handle heavier mould strings, then the indexing capability is improved, but the device complexity and cost increase
Solution Approach 1:
The indexing function is divided between two components: the pressure plate handles the initial portion of indexing, and the mould conveyor handles the remaining portion. This segmentation allows the mould conveyor to be designed with reduced strength and power requirements compared to a system where the mould conveyor must handle the entire indexing distance alone, thereby reducing device complexity and cost.
Solution Approach 2:
The pressure plate performs preliminary indexing work by advancing the mould string a first distance, which reduces the remaining distance that the mould conveyor must cover. This preliminary action allows the mould conveyor to be designed with lower force and power capabilities, reducing device complexity and investment costs.
3Force
If the pressure plate travels the full distance to index moulds, then the indexing is completed, but the cycle time increases reducing production rate
Solution Approach 1:
The indexing distance is segmented into two parts: a first distance covered by the pressure plate and a second distance covered by the mould conveyor. This segmentation allows the pressure plate to complete indexing more quickly by covering only the critical initial portion, while the mould conveyor handles the remaining distance, thereby reducing the overall cycle time and increasing production rate.
Solution Approach 2:
The pressure plate performs partial indexing action by advancing the mould string only a first distance rather than the full indexing distance. This partial action is sufficient to enable the mould conveyor to complete the indexing process more efficiently, reducing the overall cycle time and improving production rate.
Data Source
AI summary
A method and system for indexing moulds using a flaskless moulding machine and a mould conveyor are provided. The method comprises: (i) forming one or more moulds, each of the one or more moulds being added to the mould string while the mould string is stationary by being brought into contact with the mould string. Once the one or more moulds has been added to the mould string, the method continues (ii) by advancing the mould string, in a single continuous motion, a distance corresponding to the sum of the thicknesses of the one or more moulds, wherein (1) the moulding machine assists the mould conveyor in advancing the mould string during a first part of the distance, and (2) the mould conveyor advances the mould string a second part of the distance, corresponding to the remainder of the distance, without assistance from the moulding machine.