Sand Moulding Machine Adaptive Pattern Alignment
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Solution Overview
Problem
Existing sand moulding techniques fail to effectively detect and correct mutual misalignment and misorientation of adjacent mould sections during the production process, leading to defects in metal castings, as inaccuracies are not accurately detected until the castings have cooled down, resulting in significant scrap or rework.
Innovation Solution
A sand moulding machine with adjustable pattern plates controlled by a detection system that adaptsively adjusts the transverse and rotational positions of pattern plates based on real-time position detections of compacted sand mould parts, ensuring precise alignment and orientation of patterns formed in subsequent mould parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time detection and adjustment systems are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The detection system measures the position and orientation of pattern plates before the moulding process, and the pattern plates are pre-adjusted to correct positions based on these measurements. This preliminary detection and adjustment prevents misalignment from occurring in the first place, improving manufacturing precision without requiring complex real-time intervention systems
Solution Approach 2:
The detection system continuously monitors the position and orientation of pattern plates and provides feedback to the control system. This feedback loop enables automatic adjustment of pattern plates to maintain precise alignment, significantly improving manufacturing precision while the automation reduces the perceived complexity for operators
2Measurement precision
If detection systems are added to monitor mould section alignment, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Traditional mechanical alignment measurement methods are replaced with optical or electromagnetic detection systems that use light or electromagnetic fields to measure the position and orientation of pattern plates. This substitution provides highly precise measurements without complex mechanical contact systems, improving measurement precision while reducing mechanical complexity
Solution Approach 2:
The detection system creates optical or digital copies/representations of the pattern plate positions and orientations. These digital models are then processed to determine misalignment without requiring complex physical measurement apparatus, improving measurement precision while keeping the detection system relatively simple
Data Source
AI summary
The moulding machine includes a moulding chamber having at least one chamber end wall provided with a pattern plate adapted to form a pattern in a mould part and associated with a reference pattern block positioned in fixed relationship to a pattern of said pattern plate and adapted to form a reference pattern in an external face of a mould part. A detection system detects the position of a pattern face of the reference pattern of the sand mould part. A transverse and/or a rotational compaction position of a pattern plate is adjustable by means of at least one actuator. Said actuators are controlled by means of a control system on the basis of successive position detections performed by the detection system of pattern faces of reference patterns of compacted sand mould parts traveling along said path of travel.