Sand Moulding Machine Reference Pattern Block Misalignment Detection
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Solution Overview
Problem
Existing sand moulding machines lack accurate detection of mutual misalignment between adjacent sand mould parts, which can lead to errors in casting cavity formation and mould dimensions, and are unable to accurately assess parameters like mould expansion and gap width.
Innovation Solution
A sand moulding machine with a non-contact distance measuring device that uses a reference pattern block with oblique flat surfaces to measure varying distances, allowing for precise detection of misalignment and mould parameters by determining intersection points and comparing them to ideal positions, using laser-based sensors for high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional sand moulding machines are used without advanced measurement systems, then the device complexity is low, but the measurement precision and manufacturing precision of sand mould parts deteriorate
Solution Approach 1:
A reference pattern block with known geometry is introduced as an intermediary element between the moulding machine and the measurement system. This reference block provides stable, pre-defined geometric features that serve as mediators for accurate measurement without requiring complex direct measurement of the sand mould parts themselves. The reference pattern block acts as a stable mediator that translates complex mould geometry into measurable reference features.
Solution Approach 2:
Instead of directly measuring the complex sand mould parts, the system creates and measures a simplified copy - the reference pattern block with known geometric features. This copying approach allows the measurement system to work with idealized, easily measurable geometries rather than the complex, irregular shapes of actual sand moulds, thereby improving measurement precision without proportionally increasing system complexity.
2Manufacturing precision
If simple alignment methods are used, then the device complexity remains low, but the manufacturing precision of sand mould parts deteriorates
Solution Approach 1:
The system replaces complex mechanical alignment mechanisms with an optical/electronic measurement approach. Instead of using mechanical fixtures, clamps, or adjustment mechanisms to ensure precise alignment, the invention uses a non-contact measurement system that detects misalignment and provides feedback for correction. This substitution of mechanical alignment systems with measurement-based alignment improves manufacturing precision without requiring complex mechanical alignment devices.
Solution Approach 2:
The measurement system provides feedback information about the actual positions and alignments of sand mould parts. This feedback loop allows for real-time or near-real-time detection and correction of alignment errors, enabling high manufacturing precision through information-based control rather than complex mechanical precision mechanisms. The system measures actual conditions and uses this information to maintain or achieve required precision.
3Difficulty of detecting and measuring
If conventional detection methods are used, then the device complexity is low, but the ability to detect mould expansion and gap width deteriorates
Solution Approach 1:
The system transitions from single-point or simple linear measurement to multi-dimensional measurement capabilities. By using multiple measurement points and three-dimensional coordinate measurement, the system can detect not only positional misalignment but also mould expansion in multiple directions and gap widths between mould parts. This dimensional expansion of the measurement approach enables comprehensive detection of various mould parameters without requiring separate specialized devices for each parameter.
Solution Approach 2:
The measurement system is designed with multi-functionality to detect various mould parameters including misalignment, mould expansion, and gap width using a single integrated system. Rather than requiring separate detection devices for each parameter, the universal measurement system can measure multiple geometric features and derive different mould parameters from the same set of measurements, thereby improving detection capability without proportionally increasing system complexity.
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
Enables accurate detection of mutual misalignment, mould expansion, and gap width, ensuring precise formation of sand moulds and preventing faulty castings by providing detailed positional data for improved manufacturing processes.
Implementation Method 1
using laser-based sensors for high accuracy
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The moulding machine includes a moulding chamber having at least one chamber end wall provided with a pattern plate (10) adapted to form a pattern in a mould part and associated with a reference pattern block (24) 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 non-contact distance measuring device measures a distance to the reference pattern during relative displacement between the mould parts and the measuring device. The reference pattern block includes at least two flat faces (L, M, N) following one after the other in a longitudinal direction of the moulding chamber and being adapted to form a reference pattern including at least two flat surfaces following one after the other in the displacement direction. Each flat face is arranged at an oblique angle to another of the flat faces.