Robotic Sand Mold Matching for Accurate Small-Lot Production
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Solution Overview
Problem
Conventional mold manufacturing methods are inadequate for producing a wide variety of products in small lots due to limitations in shaping flasks and dimensional accuracy issues with reference patterns, particularly in small lot production.
Innovation Solution
A mold manufacturing method utilizing a robot-operated machining head for cutting mold matching surfaces and a robot-operated gripping arm for precise mold matching, with coordinate measurement sensors to ensure accurate alignment of upper and lower molds, allowing for efficient cutting and matching of sand molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional shaping flasks are used for sand blocks, then the manufacturing process is simple, but the requirement of a wide variety of products in small lot cannot be satisfied
Solution Approach 1:
The patent applies universality by using a single shaping flask for all sand blocks regardless of product type, and by using a robot-operated machining head with multiple functions (cutting, measuring, mold matching) to handle diverse product requirements. The machining head can process different sand blocks with varying dimensions and cavity requirements, making the system adaptable to a wide variety of products without requiring dedicated tooling for each product type.
2Manufacturing precision
If reference pattern blocks are used for mold matching, then the mold matching process is simplified, but dimensional accuracy cannot be guaranteed in small lot production
Solution Approach 1:
The patent replaces the conventional mechanical reference pattern block system with a robot-operated measurement and alignment system. The robot equipped with a measurement sensor automatically measures the actual dimensions of each sand block and calculates precise mold matching positions based on measured data, rather than relying on pre-fabricated reference patterns. This substitution of mechanical reference systems with automated measurement and calculation systems enables high dimensional accuracy for small lot production.
Solution Approach 2:
The patent creates a digital copy of the sand block dimensions through automated measurement, then uses this digital model to calculate and establish the mold matching positions. Instead of physically copying dimensions through reference patterns, the system digitally captures the actual sand block geometry and uses this information to guide the mold matching process, ensuring accuracy reflects the actual manufactured dimensions.
3Manufacturing precision
If conventional cutting methods are used, then the equipment is simple, but the cutting amount is large and accuracy is insufficient
Solution Approach 1:
The patent replaces conventional manual or fixed automated cutting methods with a robot-operated machining head that integrates measurement and cutting functions. The robot measures the actual sand block dimensions, calculates the precise cutting amounts needed, and executes the cutting with high precision. This substitution enables minimal cutting by accurately determining only the necessary material removal based on actual dimensions, rather than relying on large safety margins or fixed cutting paths.
Data Source
AI summary
Provided is a mold manufacturing method with which the requirement of a wide variety of products in a small lot can be satisfied. A cutting step includes forming, through cutting, mold matching surfaces in respective upper and lower molds and forming, through cutting, cavities C1 and C2 in the respective upper and lower molds with the mold matching surfaces being references. A mold matching step includes: measuring at least three points PU1 to 3 that are not located on a same straight line and that are located on the mold matching surface of the lower mold placed on a placement surface; causing recognition of Z coordinates of these respective points; measuring at least three points PL1 to 3 that are not located on a same straight line and that are located on the mold matching surface of the upper mold gripped by a gripping arm; causing recognition of Z coordinates of these respective points; and subsequently performing mold matching with the mold matching surfaces SmU and SmL of the upper and lower molds being oriented to be kept parallel to each other.