Robotic Maintenance Station for Casting Molds
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Solution Overview
Problem
Current maintenance methods for casting tools, which involve manual cleaning and coating at high temperatures, pose health risks and production interruptions due to thermal loads, dust inhalation, and prolonged downtime.
Innovation Solution
A maintenance station equipped with a robotic handling device that uses a spray device to clean the tool surface with a mixture of compressed air and abrasive particles, such as ice or salt, and applies a new coating, while a suction device captures dust and noise protection enhances safety and ergonomics, allowing for remote maintenance and minimizing production interruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning and coating is performed at the casting station, then the tool can be maintained in place, but the cleaning personnel are exposed to high temperatures and dust inhalation risks
Solution Approach 1:
The maintenance process is segmented into two separate locations: the casting station for production and a dedicated maintenance station for cleaning and coating. This spatial segmentation removes personnel from the harmful high-temperature environment while maintaining tool maintenance quality through specialized equipment at the maintenance station.
Solution Approach 2:
A robotic handling device serves as an intermediary between the casting station and maintenance station. The robot transports the mold between locations and performs automated cleaning and coating operations, eliminating direct human exposure to thermal and dust hazards while ensuring consistent maintenance quality.
2Reliability
If cleaning and coating take place at the casting station, then the tool can be maintained immediately, but production is interrupted
Solution Approach 1:
The mold is cleaned and coated in advance at the maintenance station before being returned to the casting station. This preliminary maintenance action ensures the tool is ready for production without causing interruptions, as the maintenance occurs during the robot's transport cycle or in parallel with production activities.
Solution Approach 2:
The production and maintenance operations are segmented into separate spatial and temporal zones. The casting station continues production while the maintenance station performs cleaning and coating independently, eliminating production interruptions while ensuring tool readiness through coordinated robot operations.
3Object-affected harmful factors
If automated robotic cleaning is used, then operator safety is improved, but the device complexity increases
Solution Approach 1:
The robotic handling device is designed with multi-functionality, serving both as a transport mechanism between casting and maintenance stations and as the primary manipulator for cleaning and coating operations. This universal design reduces overall system complexity compared to having separate specialized robots for each function.
Solution Approach 2:
The cleaning device and coating device are merged into a single integrated maintenance station, both mounted on the same robotic handling system. This combination eliminates the need for separate complex systems while improving operator safety through complete automation of hazardous operations.
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
This solution automates the cleaning and coating process, reducing operator exposure to heat and dust, minimizing production downtime, and ensuring consistent and efficient tool maintenance, thereby improving safety and productivity.
Implementation Method 1
a cleaning medium is sprayed or jetted onto a surface of at least one casting tool using the spraying device, wherein the cleaning medium is a mixture of compressed air and abrasive particles
Implementation Method 2
a cleaning medium is sprayed or jetted onto a surface of at least one casting tool using the spraying device, wherein the cleaning medium is a mixture of compressed air and abrasive particles
Implementation Method 3
the mold surface is coated with a sizing agent, thus applying a new coating
Data Source
Figure 1
AI summary
A maintenance station for casting molds is provided with a handling device on which a spraying device is disposed. The spraying device sprays a cleaning medium onto a surface of at least one casting mold. The cleaning medium is a mixture of compressed air and abrasive particles. A maintenance method for the casting mold in the maintenance station is also provided.