Lost Wax Casting Machine with Segmented Injection Points
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Solution Overview
Problem
Existing machines for lost wax casting face challenges such as high waste of precious metal, difficulty in controlling casting temperatures, and inefficiencies in the manufacturing process, leading to incomplete filling and quality issues in the cast objects.
Innovation Solution
A machine with a programmable logic controller and advanced temperature control systems for precise melting and injection of metal, combined with a mold design that minimizes waste and allows for separate temperature control of each injection point, reducing the need for a central main sprue and feeding sprues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a tree-shaped cluster structure with central channel and feeding sprues is used, then productivity is improved by casting multiple objects simultaneously, but loss of substance increases due to large amounts of precious metal waste in the feeding channels
Solution Approach 1:
The invention extracts and eliminates the central main sprue and feeding sprues from the traditional tree-shaped cluster structure. Each object is cast independently through its own injection point directly connected to the crucible, removing the harmful feeding channels that cause precious metal waste while preserving the ability to cast multiple objects simultaneously.
Solution Approach 2:
The invention segments the unified tree-shaped cluster structure into multiple independent injection points, each serving a single object. This segmentation eliminates the need for central and feeding sprues that connect multiple objects, thereby reducing precious metal waste while maintaining productivity through simultaneous casting of multiple objects.
2Device complexity
If a central main sprue and feeding sprues are used to distribute metal to multiple objects, then device complexity is reduced with a single injection system, but manufacturing precision deteriorates due to difficulty in controlling casting temperatures for objects of different masses
Solution Approach 1:
The invention segments the injection system into multiple independent injection points, each with its own control. This allows precise temperature management for each object based on its specific mass requirements, eliminating the temperature control difficulties associated with centralized sprue systems while maintaining reasonable device complexity through the modular nature of the independent injection points.
Solution Approach 2:
The invention applies local quality by providing tailored temperature control at each injection point according to the specific requirements of each object being cast. Objects of different masses receive appropriate temperature management at their respective injection points, ensuring manufacturing precision without requiring a complex centralized control system.
3Productivity
If large masses of metal are injected into the casting cavity, then productivity is improved by filling multiple cavities, but object-generated harmful factors increase due to turbulence and shrinkage creating defects in the cast objects
Solution Approach 1:
The invention segments the metal injection process into multiple small, independent injections at separate injection points rather than one large injection. This eliminates turbulence and shrinkage defects caused by large mass injections while maintaining productivity by simultaneously filling multiple cavities through the segmented injection approach.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces waste material, improves temperature control, and enhances the quality and homogeneity of the cast objects, while also reducing energy consumption and production time.
Implementation Method 1
an induction generator (4') adapted to melt, under the control of the programmable logic controller (1), the metal material inside the crucible (5)
Implementation Method 2
an induction generator (4') adapted to melt, under the control of the programmable logic controller (1), the metal material inside the crucible (5)
Implementation Method 3
The lower chamber is adapted to house the mold inside and to be put under vacuum so as to promote the injection of the molten metal into the mold
Data Source
Figure 1a~1b
Figure 1c
Figure 1d
AI summary
A machine (100) for melting and injecting metal material into a mold (14) for manufacturing lost wax casting objects, comprising: a controller (1); a melting chamber, operationally connected to the controller (1), comprising a crucible (5) adapted to contain metal material, the crucible (5) comprising at least one dispensing hole for the molten metal material, the melting chamber further comprising an induction generator (41), operationally connected to the controller (1), the induction generator (41) being adapted to melt, controlled by the controller (1), the metal material inside the crucible (5) of the melting chamber at a set melting temperature, the controller (1) being configured to adjust the dispensing of the molten metal material from said at least one dispensing hole of the crucible (5) of the melting chamber; an injection chamber (12) operationally connected to the controller (1), adapted to receive the molten metal material which can be dispensed from the melting chamber into an injection point (13) associated with a mold (14) of objects that can be manufactured by lost wax casting, which can be housed in the injection chamber (12). The injection chamber (12) comprises a support (18) configured to house one or more molds (14) of objects that can be manufactured by lost wax casting, each one associated with one or more injection points defining a plurality of injection points (13), said support (18) being adapted to rotate about a respective rotation axis (Al). The controller (1), for each injection point of the plurality of injection points (13), is configured to: actuate the rotation of the support (18) of said one or more molds (14) of objects about said rotation axis (Al) to position in succession an injection point of said plurality of injection points (13) coaxially with said at least one dispensing hole of the crucible (5) of the melting chamber; block the rotation of said support (18); enable the dispensing of the molten metal material from the crucible (5) of the melting chamber to the said injection chamber (12).