Tilting Gravity Casting Apparatus with Sensor-Controlled Blocking
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Solution Overview
Problem
Tilting gravity casting apparatuses struggle to fully fill complex die cavities with molten metal, leading to incomplete casting and defects such as shrinkage cavities in products like automobile knuckles.
Innovation Solution
A tilting gravity casting apparatus equipped with a block member and pressing pin, controlled by a sensor system that detects molten metal levels and initiates blocking and pressing actions to ensure complete cavity filling and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tilting gravity casting is used for complex shapes, then the casting process can be simplified, but the die cavity cannot be fully filled and casting defects occur
Solution Approach 1:
The block member blocks the runner to prevent molten metal flow before the cavity is completely filled, ensuring that the pouring action is precisely controlled to achieve complete filling without premature termination
Solution Approach 2:
The molten metal sensing sensor detects the presence or absence of molten metal in real-time during the pouring process, providing feedback to the control unit to determine when to activate the block member for blocking the runner
2Device complexity
If tilting gravity casting is used for complex shapes, then the apparatus structure can be simplified, but shrinkage cavities and casting defects cannot be prevented
Solution Approach 1:
The pressing pin is positioned and activated at the appropriate time to press the molten metal in the cavity before solidification occurs, preventing shrinkage cavities and ensuring complete filling of complex geometries
Solution Approach 2:
The control unit uses signals from the molten metal sensing sensor to determine the precise timing for activating the pressing pin, ensuring that pressing occurs when molten metal is present in the cavity to prevent defects
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
The apparatus ensures complete filling of the die cavity, reducing casting defects and improving the quality of cast products by using sensors to control the blocking and pressing operations based on molten metal detection signals.
Implementation Method 1
a first molten metal sensing sensor 24 disposed in the runner 5
Implementation Method 2
a first molten metal sensing sensor 24 disposed in the runner 5
Implementation Method 3
a pressing pin 23 for pressing the molten metal M in the cavity 6
Implementation Method 4
a block member 18 for blocking the runner 5
Implementation Method 5
the molten metal M is poured through a runner 5 into a cavity 6 of the die 2 when the die 2 is tilted
Data Source
AI summary
In a tilting gravity casting apparatus, a die includes a ladle that stores a molten metal and the molten metal is poured through a runner into a cavity of the die when the die is tilted. The apparatus includes a block member for blocking the runner, a pressing pin for pressing the molten metal in the cavity, a controller that controls operation of driving the block member and the pressing pin, and a first molten metal sensing sensor disposed in the runner. The controller is configured to start driving the block member and the pressing pin based on a detection signal outputted from the first molten metal sensing sensor.