Foundry Sand Water Adjustment via Direct Content Measurement
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Solution Overview
Problem
The existing methods for mixing and adjusting foundry sand require complex calibration to determine the correlation between water sensor measurements and water content, which is burdensome for operators and controllers, and needs periodic recalibration due to changes in sensor states and sand conditions.
Innovation Solution
A method using weight and water content measuring means, along with CB value measuring means, to iteratively adjust water supply in the sand muller, determining the necessary water amount and variation ratio through repeated measurements until the target CB value range is achieved, eliminating the need for calibration between sensor and water meter values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is performed to determine the correlation between water sensor measurements and water meter readings, then measurement precision is improved, but device complexity and operational burden increase
Solution Approach 1:
The patent extracts the water content measurement function from the complex calibration process involving water sensors and water meters. Instead of using water sensor readings that require calibration against water meter measurements, the invention directly measures water content using a water content meter, eliminating the need for calibration operations while maintaining measurement accuracy.
Solution Approach 2:
The system performs self-adjustment of water supply based on direct water content measurements. The water content meter directly provides accurate water content readings without requiring external calibration, and the control unit automatically adjusts water supply based on these readings, eliminating the need for operator intervention in calibration procedures.
2Measurement precision
If calibration is performed periodically to maintain accuracy, then measurement precision is maintained, but productivity decreases due to repeated calibration operations
Solution Approach 1:
The patent removes the periodic calibration requirement by extracting the direct measurement capability from the indirect sensor-based measurement system. The water content meter provides accurate readings without needing periodic calibration, allowing continuous mixing operations without interruption for calibration maintenance.
3Manufacturing precision
If feedback control is implemented using water sensor data, then manufacturing precision is improved, but ease of operation deteriorates due to complex calibration requirements
Solution Approach 1:
The system achieves automated feedback control where the water content meter directly provides accurate water content measurements to the control unit, which automatically adjusts water supply. This self-service mechanism eliminates the need for operators to perform calibration procedures while maintaining precise water content control throughout the mixing process.
Data Source
AI summary
A mixing and adjusting method for foundry sand includes calculating a total supplied water amount until a compactability (CB) value of mixed sand becomes larger than a lower limit value of a target CB value range, determining the total supplied water amount as a predetermined amount of water associated with an electric resistance of the foundry sand, and determining a ratio of a variation in the CB value corresponding to an additionally supplied water amount from the additionally supplied water amount during an additional water pouring and the CB value of the mixed sand.