Modular Temperature Sensor Array for Metal Casting Moulds
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Solution Overview
Problem
The existing mold designs for metal casting with multiple temperature measuring devices require high installation effort and are prone to errors due to complex connections and positioning issues, leading to significant deviations in measurement results.
Innovation Solution
The temperature measuring devices are arranged in a preassembled module with precise positioning, which is then attached to the mold wall, allowing for optimal heat transfer and minimizing installation effort and measurement deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If temperature measuring devices are installed individually in the mold plate, then the measurement results can be obtained, but the installation effort and complexity increase significantly
Solution Approach 1:
The temperature measuring devices are segmented into a modular assembly that can be pre-configured and tested separately before installation in the mold plate. This module contains multiple thermocouples arranged in a specific pattern, allowing the complex installation task to be divided into simpler steps: installing the module as a unit rather than individual sensors, reducing installation time and complexity while maintaining measurement precision.
Solution Approach 2:
The temperature measuring devices are pre-assembled and pre-positioned in the correct spatial arrangement before installation in the mold plate. The modular assembly is prepared in advance with proper spacing and orientation, so that during final installation, the entire module is installed as a complete unit rather than individually positioning each sensor, thereby reducing installation effort while preserving measurement accuracy.
2Measurement precision
If thermocouples are positioned close together to monitor the cooling strand continuously, then measurement coverage is improved, but positioning accuracy becomes more difficult to maintain
Solution Approach 1:
The temperature measuring devices are segmented into a modular assembly that maintains precise spatial relationships between adjacent thermocouples. The module is designed as a single unit with pre-established positioning, allowing continuous monitoring coverage while preventing positioning errors that would occur if each sensor was installed individually. The modular structure ensures consistent spacing even at distances as small as 10 mm between sensors.
Solution Approach 2:
The precise positioning of temperature measuring devices is performed in advance during module assembly in the manufacturer's workshop, rather than during final installation in the mold. This preliminary positioning allows for controlled, precise arrangement of sensors at close distances (e.g., 10 mm spacing) under optimal manufacturing conditions, ensuring positioning accuracy is maintained even when continuous coverage requires minimal spacing between sensors.
3Ease of operation
If individual thermocouples are connected via separate couplings, then connection flexibility is improved, but the risk of accidental damage and connection errors increases
Solution Approach 1:
Multiple separate thermocouple connections are merged into a single integrated module assembly. The modular structure combines multiple temperature measuring devices and their connections into one unit, reducing the number of separate coupling operations during installation. This merging reduces the probability of accidental damage to individual connections while maintaining the flexibility needed for proper installation, as the entire module is installed as a complete assembly rather than individual sensors with separate connections.
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 approach reduces installation complexity and enhances measurement accuracy by enabling precise positioning of temperature sensors, improving heat transfer, and minimizing measurement errors, thus providing reliable and informative results.
Implementation Method 1
a plurality of temperature measuring devices, which are arranged in a wall in the mold for detecting the temperature distribution in the wall during the casting operation
Implementation Method 2
The heat transfer can be improved, for example, by using a heat-conducting paste, which, however, has to withstand the high temperatures that occur in the mold during casting
Data Source
Figure 1a~1c
Figure 2
Figure 3
AI summary
The invention relates to a mould for casting metal, having a plurality of temperature measuring devices (300) that are arranged in a wall (100) of the mould in order to detect the temperature distribution at that location. In order to make it easier to install the plurality of temperature measuring devices in the wall and in order to increase the reliability of the measurement results from said devices, it is proposed according to the invention to arrange the temperature measuring devices (300) such that they are positioned fixedly with respect to one another in a module (400), such that the temperature measuring devices together with the module form a structural unit which can be preassembled before the mould is installed. The structural unit is then fastened in or to the wall of the mould as the mould is being assembled.