Molten Metal Traceability Using Pseudo and Visual Codes
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Solution Overview
Problem
Existing methods fail to effectively collect, track, and store data of molten metal during casting processes due to the loss of engraved codes during melting, leading to complexity and lack of historical information access in high-volume production.
Innovation Solution
A marking method involving pseudo codes and visual codes is employed, where metal information is stored in a memory unit, and a visual code is matched with a pseudo code after molding, enabling data collection, tracking, and storage throughout the melting and casting processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If conventional engraving methods are used to store codes on metal materials, then data can be stored on the material itself, but the code disappears during the melting process in casting applications
Solution Approach 1:
The data storage system is segmented into two distinct parts: a pseudo-code that travels with the molten metal through the casting process, and a visual code that is applied to the final product. This segmentation allows the identification system to adapt to different stages of the manufacturing process without requiring a single complex system to handle all scenarios.
Solution Approach 2:
The pseudo-code acts as an intermediary between the raw material stage and the final product stage. It temporarily stores identification information in a form that survives the melting process, then facilitates the transfer of this information to the visual code on the final product, bridging the gap created by the melting process.
2Loss of time
If multiple codes are assigned for different production stages, then data can be tracked throughout the process, but the system becomes complex and error-prone
Solution Approach 1:
The pseudo-code is assigned to the molten metal before the casting process begins, establishing the identification trail in advance. This preliminary action ensures that tracking information is already in place before the complex melting and casting operations occur, eliminating the need for post-process identification workarounds.
Solution Approach 2:
The system creates a copy of the identification information in two forms: the pseudo-code that survives the melting process and the visual code that appears on the final product. This copying mechanism ensures that the identification data is preserved and accessible throughout the manufacturing process without requiring complex transformation or retrieval systems.
3Reliability
If only production data is stored, then the storage system remains simple, but it is not possible to determine problems caused by the condition of the used metal
Solution Approach 1:
The memory unit is designed with multi-functionality, serving both as a storage location for the pseudo-code and as a comprehensive database for production parameters, environmental conditions, and quality data. This universal storage solution allows the system to handle diverse data types without requiring separate specialized storage systems for each data category.
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 comprehensive data storage and easy access to production information by matching visual codes with pseudo codes, ensuring reliable and practical data management from raw material to final product.
Implementation Method 1
melting said piece of metal
Data Source
AI summary
The present invention discloses a marking method for collecting, tracking and storing data of a molten metal during melting and casting processes. Said marking method comprises the steps of: receiving at least one piece of metal to be melted; storing at least one information of the received metal ingot in a memory unit; melting said piece of metal; assigning at least one pseudo code to the melted piece of metal; storing the pseudo code assigned to the molten metal in the memory unit; molding the melted piece of metal; storing at least one data related to the molten metal and/or environmental conditions during the melting and/or molding processes in the memory unit; assigning a visual code to the final demolded product; matching the visual code assigned to the final product with the pseudo code stored in the memory unit.