Mold Molding Apparatus Real-Time Strength Control
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Solution Overview
Problem
Existing mold molding apparatuses cannot effectively measure and adjust casting mold strength in real-time, leading to difficulties in successively molding casting molds with the necessary strength, as strength determination occurs after mold formation, preventing immediate corrective action in the next cycle.
Innovation Solution
Incorporating molding sensors to measure pressure on pattern plates and squeeze feet or boards, with a control device that adjusts operation parameters such as squeeze pressure, aeration pressure, and setting positions based on real-time measurements to ensure casting molds meet strength requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If strength measurement is performed after mold discharge using force sensors, then casting mold strength can be determined, but it is not possible to make use of the results during molding or for the next cycle
Solution Approach 1:
The patent applies preliminary action by measuring the pressure of molding sand during the molding process itself, rather than after mold discharge. The molding sensor measures pressure while the mold is being formed, and the control device uses this information to adjust molding parameters for the current and next cycles, enabling proactive quality control before defects occur
Solution Approach 2:
The patent implements feedback by creating a closed-loop control system where the molding sensor continuously measures sand pressure, the control device processes this information to determine mold strength, and the system automatically adjusts molding parameters based on the results. This real-time feedback enables continuous improvement of casting mold quality across successive cycles
2Loss of information
If pressure measurement is performed after molding is complete, then casting mold hardness can be known, but corrective actions cannot be implemented during the molding process
Solution Approach 1:
The system performs preliminary measurement of molding sand pressure during the active molding process, capturing critical process information while it is being generated. This allows the control device to analyze and respond to molding conditions in real-time, adjusting parameters before the molding cycle completes to prevent defects
Solution Approach 2:
The molding sensor provides continuous feedback during the molding process, enabling the control device to make real-time adjustments to molding parameters. This closed-loop control ensures that corrective actions are implemented during the process rather than after completion, improving both quality and operational efficiency
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
Enables the stable and successive molding of casting molds with the necessary strength by allowing immediate corrective actions during the molding process, improving precision and preventing defective mold production.
Implementation Method 1
a molding sensor that measures a pressure of molding sand exerted on a surface of one or both of a pattern plate and a squeeze foot
Data Source
AI summary
A mold molding apparatus can successively mold casting molds having the necessary casting mold strength, and a method for controlling the mold molding apparatus. A molding sensor measures a pressure of molding sand exerted on a surface of one or both of a pattern plate and a squeeze foot, or on a surface of one or both of a pattern plate and a squeeze board; and a control device that controls operation of the mold molding apparatus based on outputs from the molding sensors.