Sand Core Machine Electromechanical Cylinder Control
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Solution Overview
Problem
Existing sand core casting machines face challenges in achieving better control of the casting process while minimizing costs, particularly due to the use of mechanical linkage mechanisms that increase manufacturing costs and lead to unbalanced forces.
Innovation Solution
A sand core making machine utilizing electromechanical cylinders with a control unit to vary the pressing force during sand filling and compacting, eliminating the need for intermediate linkage mechanisms and allowing for a simpler, more compact design by directly attaching cylinders to the core box closing frame and head, with a control unit that commands the cylinders to adjust force during transient phases of operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a mechanical linkage mechanism is used to achieve high pressing force, then the pressing force is increased, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the mechanical linkage mechanism with an electromechanical cylinder directly attached to the core box closing frame. The electromechanical cylinder uses an electric motor with a screw mechanism to generate high pressing force, eliminating the need for complex mechanical linkages while maintaining the required force output.
Solution Approach 2:
The patent extracts and removes the intermediate mechanical linkage mechanism from the system, directly connecting the electromechanical cylinder to the core box closing frame. This simplification eliminates unnecessary components while preserving the essential function of applying pressing force.
2Force
If a mechanical linkage mechanism is used to achieve high pressing force, then the pressing force is increased, but the manufacturing cost increases
Solution Approach 1:
The electromechanical cylinder replaces the mechanical linkage mechanism, reducing manufacturing complexity and cost. The standardized electromechanical component is easier and less expensive to manufacture than a custom mechanical linkage system designed to achieve the same force multiplication.
3Force
If a mechanical linkage mechanism is used to achieve high pressing force, then the pressing force is increased, but the force distribution becomes unbalanced
Solution Approach 1:
The electromechanical cylinder provides direct, controlled force application without the force distribution issues inherent in mechanical linkages. The electric motor with screw mechanism ensures uniform force transmission to the core box closing frame, eliminating the unbalanced force distribution caused by mechanical linkages.
Solution Approach 2:
The control unit monitors and adjusts the electromechanical cylinder operation to ensure uniform pressing force distribution across the core box, preventing the unbalanced forces that occur with mechanical linkage mechanisms.
4Device complexity
If electromechanical cylinders are used to move the core box closing frame and head, then the device complexity is reduced, but the control precision during sand filling and compacting is insufficient
Solution Approach 1:
The control unit receives feedback from sensors monitoring the position and force of the electromechanical cylinders, continuously adjusting their operation to achieve precise control during sand filling and compacting phases. This feedback mechanism enables the simplified electromechanical system to achieve the required precision.
Solution Approach 2:
The control unit dynamically adjusts the operation of the electromechanical cylinders based on the specific phase of the casting process (sand filling, compacting, etc.), varying the force and speed to optimize performance for each operation while maintaining overall system simplicity.
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 enables precise control of the casting process, reduces manufacturing costs, and achieves a more homogeneous pressing force, enhancing the efficiency and effectiveness of the sand core production process.
Implementation Method 1
electromechanical cylinders mounted on the main frame and configured for moving the core box closing frame and the head and exerting a pressing force on the core box
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention is directed to a core making machine (2) comprising a main frame (4); a lower support assembly (6) mounted on the main frame (4), for supporting a core box; a core box closing frame (10), vertically movable on the main frame (4); a head (14) for sand filing and compacting, above the core box closing frame (10) and vertically movable on the main frame (4); electromechanical cylinders (18, 20) mounted on the main frame (4) and configured for moving the core box closing frame (10) and the sand filing and compacting frame (14) and exerting a pressing force on the core box; and a control unit of the electromechanical cylinders (18, 20), configured for varying the force exerted by said electromechanical cylinders during sand filling and/or sand compacting.