Magnetic Insert Mounting for Damage-Free Casting Mold Positioning

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Solution Overview

Problem

Existing insert mounting devices for casting molds require complex structures with guide rods and lock mechanisms, which can lead to mold damage if guide rods are not inserted smoothly and complicate the mold and robot design.

Innovation Solution

An insert mounting device using a robot with a gripping portion that secures a predetermined clearance between the insert and the insert housing portion, utilizing a magnet to attract the insert, eliminating the need for guide rods and lock mechanisms, thus simplifying the structure and preventing mold damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If guide rods and lock mechanisms are used to position and secure the insert, then the insert can be firmly fixed in the mold, but the structure becomes complicated and the risk of mold damage increases

Engineering Contradiction:

Improveinsert fixation reliabilityVSAvoidmold structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical guide rod and lock mechanism system with a magnetic field-based positioning and fixation system. Magnets embedded in the mold attract and hold the insert without physical contact, eliminating the need for guide rods, guide holes, and lock mechanisms while achieving reliable insert positioning and securing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces magnetic force as an intermediary between the mold and the insert. Instead of direct mechanical contact through guide rods and locks, the magnetic field acts as a mediator to position and secure the insert, reducing mechanical complexity and the risk of mold damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If guide rods are inserted into guide holes to position the insert, then positioning accuracy can be achieved, but the guide rods and mold may be damaged if insertion is not smooth

Engineering Contradiction:

Improveinsert positioning accuracyVSAvoidmold damage risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical insertion process of guide rods into guide holes with a magnetic attraction process. The magnets in the mold automatically guide and position the insert without physical insertion, eliminating the risk of damage from forced insertion while maintaining positioning accuracy through magnetic alignment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses magnetic force to provide a cushioning effect during the positioning process. The magnetic attraction gradually pulls the insert into position, preventing sudden impacts or forced insertions that could damage the mold, thereby cushioning the positioning action before final contact.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If four guide holes and lock mechanisms are provided in the mold, then the insert can be securely fixed, but the mold and robot structures become complicated

Engineering Contradiction:

Improveinsert fixation securityVSAvoidoverall system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the entire mechanical fixation system (four guide holes, lock mechanisms, and corresponding guide rods) with a magnetic fixation system. Magnets embedded in the mold provide secure insert fixation through magnetic attraction, eliminating the need for multiple guide holes and lock mechanisms, thereby reducing overall system complexity while maintaining fixation security.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the guide rod and lock mechanism components from the system, retaining only the essential fixation function through magnetic attraction. This extraction eliminates unnecessary structural elements, simplifying both the mold and robot designs while maintaining insert security.

Inventive Principle:

Principle #2Taking out (Extraction)

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

The solution prevents mold damage and allows for a simpler structure by using magnetic attraction to hold the insert in place, reducing the complexity of the mold and robot design while ensuring accurate positioning.

Implementation Method 1

a magnet is embedded in the insert housing portion of one of the fixed mold and the movable mold... causes the insert to be attracted to the insert housing portion by the magnet

Methodology Applied

Scientific EffectMagnetic attraction: Magnetism

Data Source

PatentUS11548063B2Insert mounting device

Publication Date: 2023.01.10 HONDA MOTOR CO LTD

AI summary

An insert (cover member) is formed of an iron-based alloy. A casting mold is constituted by a fixed mold and a movable mold. An insert housing portion (cover housing portion) for housing the insert is formed in a separation surface between the fixed mold and the movable mold, and a magnet is embedded in the insert housing portion of either the fixed mold or the movable mold. A robot grips the insert with a gripping portion (hand) to convey the insert to a position facing the insert housing portion, releases the insert at the facing position in a state where a predetermined clearance is secured between the insert and the insert housing portion, and causes the insert to be attracted to the insert housing portion by the magnet.