Self-hardening Mold Apparatus with Shaft Detector Feedback
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Solution Overview
Problem
Conventional self-hardening molding machines face errors in position control of the discharge port due to voltage fluctuations and mechanical system variations, leading to inaccurate reproduction of molding operations.
Innovation Solution
The self-hardening molding apparatus incorporates a conveyor arm and kneading arm with pivot motors, pulse generators, and shaft detectors to calculate and correct rotation angles, ensuring accurate positioning of the discharge port through teaching storage and playback operations, using a programmable logic controller to store and execute sequence control programs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic control is implemented using pulse counting from rotary encoders, then productivity increases through automation, but manufacturing precision deteriorates due to position control errors from voltage fluctuation and friction variation
Solution Approach 1:
The system implements feedback by continuously monitoring the actual position of the discharge port through shaft detectors during automatic operation, comparing it with the taught position, and correcting deviations in real-time. This closed-loop feedback mechanism eliminates position control errors caused by voltage fluctuation and friction variation, maintaining manufacturing precision while preserving automation benefits
Solution Approach 2:
The invention replaces the purely mechanical pulse-counting position detection system with an electrical detection system using shaft detectors (encoders) that directly measure the actual position of the discharge port. This substitution transforms the open-loop mechanical positioning into a closed-loop electrical control system, enabling accurate position feedback and correction without relying on cumulative pulse counting
2Device complexity
If simple pulse counting is used for position detection, then device complexity is reduced, but manufacturing precision deteriorates due to error accumulation in position control
Solution Approach 1:
The system introduces feedback by using shaft detectors to continuously monitor the actual position of the discharge port during automatic operation. The detected position information is fed back to the control device, which compares it with the taught position and generates correction commands. This feedback mechanism prevents error accumulation while maintaining relatively simple device architecture
Solution Approach 2:
The invention introduces shaft detectors as intermediary devices between the mechanical driving system and the control system. These detectors act as mediators that convert mechanical position information into electrical signals, enabling accurate position measurement and feedback without significantly increasing overall system complexity
Data Source
AI summary
Teaching storage means stores teaching data created on the basis of signals from a first pulse generator, a first shaft detector, a second pulse generator, and a second shaft detector, in a storage unit as a sequence control program of molding operation of a self-hardening mold when teaching operation of throwing kneaded self-hardening foundry sand from a discharge port into a molding flask is performed by manually moving a conveyor arm and a kneading arm. Molding playback means reads out the sequence control program from the storage unit to control and drive a first pivot motor and a second pivot motor on the basis of the sequence control program to pivot the conveyor arm and the kneading arm, and then throws the self-hardening foundry sand from the discharge port of the kneading arm into the molding flask to reproduce the molding operation.