Molding System Nozzle Clogging Detection via Pressure Time
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Solution Overview
Problem
Existing molding systems face challenges in accurately detecting nozzle clogging, leading to potential molding defects due to insufficient sand filling.
Innovation Solution
A molding system that includes a tank, nozzle, and control unit, where the control unit outputs information on nozzle clogging based on the time it takes for pressure to reach a predetermined level during sand filling, allowing for mechanical detection and prevention of clogging, and includes features like alarm issuance, image analysis, and adjusted sand cutter operations to manage clogging and mold integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a worker manually determines clogging of the nozzle by observing pressure graphs, then the system can detect clogging, but the detection accuracy is insufficient and may lead to molding defects
Solution Approach 1:
The patent replaces the manual visual inspection method with an automated image recognition system using cameras and AI processing. The system captures images of the pressure graph and automatically analyzes them to detect clogging conditions, eliminating human subjectivity and improving detection accuracy and consistency.
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the pressure sensor data and the clogging determination. The camera captures the pressure graph, the control unit processes the image to extract pressure values, and then determines clogging based on processed data rather than raw visual observation, enhancing measurement precision.
2Measurement precision
If the system uses automated image recognition to detect clogging, then detection accuracy improves, but the device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it controls the sand supply, processes the captured images to extract pressure data, determines clogging conditions, and controls the sand cutter. By making the control unit multi-functional, the patent avoids adding separate dedicated devices for each function, thereby limiting the increase in overall system complexity.
Solution Approach 2:
The system uses its existing display to show the pressure graph, which then serves as the input for image recognition. The same control unit that manages sand supply also handles image processing and clogging determination. This self-service approach allows the system to leverage existing components for new functions without requiring entirely separate systems.
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 system effectively detects and addresses nozzle clogging, preventing molding defects and ensuring accurate sand filling, while also enabling detailed image analysis and controlled sand mold processing.
Implementation Method 1
a relationship where arrival time from the start of sand filling until the pressure reaches a predetermined pressure is shorter than the initial arrival time obtained in advance is satisfied
Data Source
AI summary
A molding system molding a sand mold includes a flask, a tank connected to a compressed air source, including an opened end part, and configured to internally store sand, a nozzle attached to the end part of the tank and configured to guide the sand in the tank into the flask, and a control unit configured to output information about clogging of the nozzle when, during sand filling in which the sand in the tank is introduced into the flask through the nozzle, a relationship where arrival time from the start of sand filling until the pressure reaches a predetermined pressure is shorter than the initial arrival time obtained in advance is satisfied.