Foundry Sand Loss-on-Ignition Estimation via Machine Learning
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Solution Overview
Problem
The determination of loss-on-ignition in foundry sand is time-consuming, requiring 120 minutes, which burdens foundrymen and hinders the optimization of sand reclaimer and mixing machine operations, leading to decreased casting quality.
Innovation Solution
A machine learning-based system that estimates loss-on-ignition using a learned model, processing sand weight, property, additive, and calcination environment data to predict loss-on-ignition in a shorter time, specifically within 10 minutes, allowing for efficient operation optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional drying and calcination method is used to determine loss-on-ignition, then measurement accuracy is ensured, but measurement time becomes excessively long (120 minutes or more)
Solution Approach 1:
The patent applies preliminary action by performing drying and partial calcination in advance, then storing the pre-processed foundry sand for later rapid measurement. The foundry sand is dried at 105°C for 24 hours and calcined at 1000°C for 1 hour beforehand, so that when measurement is needed, only a final 1-hour calcination is required, reducing the critical measurement time while maintaining accuracy.
Solution Approach 2:
The patent segments the traditional 120-minute loss-on-ignition determination process into distinct phases: a preprocessing phase (drying at 105°C for 24 hours plus calcination at 1000°C for 1 hour) and a measurement phase (final calcination at 1000°C for 1 hour). This segmentation allows the time-consuming drying and initial calcination to be performed separately in advance, enabling rapid repeated measurements without repeating the entire process.
2Measurement precision
If traditional loss-on-ignition determination is performed, then accurate resin content measurement is achieved, but operational optimization is delayed due to long measurement time
Solution Approach 1:
The patent enables operational optimization by performing preliminary drying and calcination treatments in advance, then conducting rapid loss-on-ignition measurements that take only 1 hour. This allows foundry operations to quickly determine resin content and adjust sand reclaimer and mixing machine conditions in a timely manner, improving productivity while maintaining measurement accuracy for operational decision-making.
3Manufacturing precision
If sand reclaimer and mixing machine operations are optimized based on loss-on-ignition, then casting quality improves, but the long measurement time prevents real-time optimization
Solution Approach 1:
The patent resolves the timing issue for quality optimization by performing preliminary drying and calcination in advance, then conducting rapid 1-hour loss-on-ignition measurements. This provides timely feedback on resin content, allowing operators to adjust sand reclaimer and mixing machine conditions based on current data, thereby maintaining high casting quality without the delays inherent in traditional 120-minute measurement methods.
Data Source
AI summary
An object is to accurately estimate loss-on-ignition in a short time. A loss-on-ignition estimation apparatus includes at least one processor configured to carry out an estimation step, the estimation step including estimating the loss-on-ignition of foundry sand with use of a learned model constructed by means of machine learning. The learned model is configured to receive, as input, (1) sand weight data relating to a weight of the foundry sand detected in a calcination period and (2) at least one of (i) sand property data relating to one or more properties of the foundry sand, (ii) additive data relating to one or more additives added to the foundry sand, and (iii) calcination environment data relating to a calcination environment detected in the calcination period. The learned model is configured to generate, as output, an estimated loss-on-ignition of the foundry sand.