Modular Turntable Assembly Cell for Sand Mold Production

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Solution Overview

Problem

Current conveyor-based mold assembly lines in foundries are inflexible, prone to shutdowns due to robot failures or core supply interruptions, require large areas, and lack the ability to produce multiple mold designs simultaneously, leading to high capital and operating costs and reduced productivity.

Innovation Solution

A modular assembly system featuring a turntable-based mold assembly cell with multiple work stations and robots that can rotate to access cores from various angles, allowing for flexible assembly sequences and simultaneous operation across multiple stations, enabling the production of different mold designs and continued operation even if one cell fails.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conveyor-based assembly lines are used for mold assembly, then automated core positioning is achieved, but the system lacks flexibility and stops entirely when one robot fails or core supply is interrupted

Engineering Contradiction:

Improveassembly line continuityVSAvoidflexibility to handle different mold designs

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The assembly line is divided into independent modular assembly cells, each capable of operating autonomously. Each cell has its own robots, conveyors, and core supply systems, allowing one cell to fail without stopping the entire production line. This segmentation provides both reliability through redundancy and flexibility through reconfigurability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses programmable robots and controllable conveyors that can dynamically adjust their operations based on real-time conditions. When a robot fails or core supply is interrupted, the system can dynamically reroute workpieces to alternative cells or adjust assembly sequences, maintaining production continuity while adapting to changing requirements.

Inventive Principle:

Principle #15Dynamics

2Productivity

If conveyor-based assembly lines with linear layout are used, then automated assembly is achieved, but large factory area is required and only one mold design can be produced per product run

Engineering Contradiction:

Improveautomated assembly outputVSAvoidfactory area occupation

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The system transitions from a linear one-dimensional conveyor layout to a two-dimensional modular grid arrangement of assembly cells. This allows workpieces to be routed through multiple cells in various sequences, reducing the total area required while maintaining high productivity through parallel processing across multiple cells.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Each modular assembly cell is designed with universal capabilities to assemble different mold designs by reprogramming robots and reconfiguring tooling. This multi-functionality eliminates the need for dedicated production lines for each mold design, reducing factory area while maintaining high productivity through flexible resource utilization.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If conveyor-based assembly lines are used, then sequential core assembly is achieved, but a large number of robots are required due to linear movement constraints

Engineering Contradiction:

Improvecore positioning accuracyVSAvoidnumber of robots required

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The assembly process is segmented into discrete operations distributed across multiple modular cells. Each cell handles specific assembly tasks with fewer robots, reducing the total robot count while maintaining positioning precision through localized, specialized robotic systems rather than requiring numerous robots in a single linear line.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Modular conveyors and transfer mechanisms act as intermediaries between assembly cells, transporting workpieces precisely between stations without requiring robots to perform all positioning functions. This reduces the robot count while maintaining manufacturing precision through coordinated robotic-conveyor systems in each cell.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11065677B2Automated assembly cell and assembly line for producing sand molds for foundries

Publication Date: 2021.07.20 NEMAK SAB DE CV

AI summary

A mold assembly cell for sand mold production comprising a turntable wherein sand cores and other mold parts (which together cooperate to define the casting cavity of the sand mold) are automatically and progressively assembled following a sequential pre-programmed schedule by programmable robots located in proximal relationship with the turntable and a core shooting machine. The assembly turntable rotates clockwise or counterclockwise to permit placement of progressively more-complete mold packages in each of at least three assembly stations to allow the robots to reach the molds being assembled at different angles for simultaneously setting the sand cores and other parts of the mold according to said pre-programmed assembly schedule. Also a mold assembly line comprising a plurality of the foregoing assembly cells to form sand molds for casting complex-geometry aluminum parts, such as aluminum engine blocks and cylinder heads, with greater flexibility, efficiency and productivity.