Foundry Sand Reserve Control for Aging Time Stability
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Solution Overview
Problem
Existing methods fail to appropriately manage the aging time of foundry sand, leading to inconsistent supply to foundry sand-related devices due to difficulties in measuring and securing the required aging time during storage.
Innovation Solution
A foundry sand reserving system and method that includes reserving units, control devices, and measurement instruments to manage and control the charge and supply amounts of foundry sand based on predetermined aging times, ensuring appropriate aging time is secured before supply to foundry sand-related devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foundry sand is reserved in a reserving unit for aging time, then the quality and consistency of foundry sand is improved, but it becomes difficult to measure and manage the aging time for each batch of foundry sand
Solution Approach 1:
The system divides the reserving unit into multiple segments or zones with different reserve amounts, allowing independent management and measurement of aging time for each segment. This enables precise tracking of aging time for different batches of foundry sand while maintaining quality consistency through controlled reserve amounts in each segment.
Solution Approach 2:
The control device continuously monitors the reserve amount and aging time, providing feedback to adjust the supply amount dynamically. This feedback mechanism ensures that the aging time is precisely measured and maintained for each batch of foundry sand, resolving the measurement difficulty while preserving quality consistency.
2Productivity
If the supply amount of foundry sand is increased to meet production demand, then the productivity is improved, but the aging time required for quality assurance cannot be secured
Solution Approach 1:
The system performs preliminary actions by pre-reserving foundry sand in controlled amounts that guarantee the required aging time before supply. The control device calculates and maintains reserve amounts that ensure aging time requirements are met in advance, allowing high productivity without compromising quality assurance.
Solution Approach 2:
The control device dynamically adjusts the supply amount based on real-time monitoring of reserve amount and aging time. This dynamic adjustment allows the system to maximize supply amount while ensuring that sufficient reserve sand with adequate aging time is always available, resolving the conflict between productivity and aging time requirements.
3Productivity
If multiple batches of foundry sand are stored together to ensure continuous supply, then the productivity is improved, but the aging time management becomes inconsistent
Solution Approach 1:
The system segments the stored foundry sand into distinct batches with individually tracked reserve amounts and aging times. This segmentation allows multiple batches to be stored simultaneously for continuous supply while maintaining consistent aging time management through separate control of each batch's reserve amount and supply timing.
Data Source
AI summary
A foundry sand reserving method includes reserving, acquiring, setting, and controlling. The reserving includes reserving foundry sand capable of being supplied to a foundry sand related device in at least one reserving unit. The acquiring includes acquiring a reserve amount of the foundry sand in at least one reserving unit, a charge amount of the foundry sand to the reserving unit, and a supply amount of the foundry sand to a foundry sand related device. The setting includes setting a threshold for the reserve amount based on a predetermined aging time of the foundry sand and the charge amount and the supply amount acquired in the acquisition step. The controlling includes controlling at least one selected from the group consisting of the charge amount and the supply amount based on the reserve amount acquired in the acquiring step and the threshold set in the setting step.