Moulding Device Dynamic Core Shape Control
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Solution Overview
Problem
Traditional molding devices for hollow turbine blades face challenges in maintaining core shape accuracy due to manufacturing dispersions and wax forces, risking core breakage and inadequate stress adaptation during the lost-wax casting process.
Innovation Solution
A molding device with dynamic deformation control means, incorporating force monitoring and a control unit to adjust core shape in real-time within manufacturing tolerances, minimizing applied forces and preventing core breakage by dynamically deforming the core along multiple directions based on measured forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the core is held in static indeterminacy conditions with multiple supports to over-stress and deform the core to its theoretical geometry, then the core shape accuracy is improved, but the core is at high risk of breaking
Solution Approach 1:
The patent applies dynamics by replacing static indeterminacy conditions with dynamic control. The core is held by a variable number of supports that can be activated or deactivated based on real-time force measurements. This allows the system to adapt from an over-constrained state (high stress) to an optimally constrained state (minimal stress), preventing core breakage while maintaining shape accuracy through active deformation control during the injection process.
Solution Approach 2:
The patent implements feedback by using force sensors to continuously monitor the forces exerted on the core during wax injection. The control unit processes this force information and adjusts the support configuration accordingly. This closed-loop feedback mechanism enables the system to detect when the core is approaching its stress limit and automatically reduce the number of active supports to prevent breakage, while still maintaining sufficient constraint for accurate deformation.
2Manufacturing precision
If supports are adjusted and repositioned using CMM monitoring to counter shape dispersions, then the core shape accuracy is improved, but the process requires immobilization of the molding device and additional time
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple supports in the molding device, ready to be activated as needed. Rather than requiring time-consuming adjustment and repositioning during the process, the supports are already in place and can be quickly activated or deactivated based on real-time force measurements. This eliminates the need for immobilization and CMM monitoring while maintaining precise control over core deformation.
Solution Approach 2:
The patent replaces the mechanical CMM monitoring and manual adjustment system with an automated force-based control system. Force sensors continuously monitor the core during injection, and the control unit automatically adjusts the support configuration without requiring mechanical repositioning or device immobilization. This substitution eliminates the time-consuming manual adjustment process while maintaining or improving shape accuracy through real-time adaptive control.
3Manufacturing precision
If the core is deformed to compensate for manufacturing dispersions, then the dimensional compliance with the hollow blade is improved, but the core is over-stressed and presents a high risk of breaking
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the number of active supports based on real-time force measurements. The system changes the constraint parameter (number of supports) in response to the actual forces exerted on the core during injection. This allows the core to be deformed sufficiently to compensate for manufacturing dispersions and achieve dimensional compliance, while simultaneously reducing the number of active supports to minimize stress and prevent breakage.
Data Source
AI summary
A moulding device (1) for moulding a material around a core (2), comprising a hollow moulding enclosure (3) suitable for receiving the core (2), and means for controlling the shape of the core (2) in the hollow enclosure (3), the control means comprising means for deforming the core (2). The control means further comprise force control means and a control unit (8) suitable for actuating the deformation means in accordance with information provided by the force control means.