Automated Wax Tree Assembly Using Flexible Branches

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Solution Overview

Problem

The lost wax process for casting is highly labor-intensive, particularly for assembling large and complex wax tree assemblies, which requires skilled artisans and is not efficiently automated, necessitating a method to connect wax runner pieces and adapt wax patterns accurately.

Innovation Solution

Automated equipment is used to flex and heat disconnected sections of wax patterns and runners to bring them into proximity, allowing for assembly without damage, and then moving them slightly apart to create a weld, facilitating the creation of a complete wax tree for casting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated equipment is used to assemble wax trees, then productivity and labor efficiency are improved, but the complexity of handling large and complex wax tree assemblies worsens automation difficulty

Engineering Contradiction:

Improveassembly efficiencyVSAvoidwax tree assembly complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The wax tree assembly process is divided into separate stages: heating disconnected sections to soften wax, flexing sections to change their shape, and joining sections together. This segmentation allows automated equipment to handle complex assemblies by breaking down the assembly process into manageable, repeatable operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies thermal energy to change the physical state of wax from solid to softened state, enabling flexing and assembly operations. By controlling temperature parameters, the system can soften specific sections of the wax tree to facilitate automated manipulation and joining without damaging the overall structure.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If disconnected sections of wax tree are heated and flexed to bring into proximity, then assembly accuracy is improved, but the risk of damaging the wax tree worsens

Engineering Contradiction:

Improveassembly accuracyVSAvoidwax tree damage risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

Heating is applied locally to specific disconnected sections of the wax tree rather than the entire assembly. This localized thermal treatment softens only the portions needed for flexing and assembly, maintaining the structural integrity and temperature stability of other sections, thereby preventing damage while achieving assembly precision.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system dynamically adjusts the flexibility of wax tree sections by controlling temperature in real-time. Sections are heated to become flexible for positioning and joining, then cooled to regain rigidity once assembled, allowing the material to transition between states as needed for precise assembly without permanent damage.

Inventive Principle:

Principle #15Dynamics

3Reliability

If skilled artisans perform wax tree assembly by hand, then assembly quality is maintained, but labor intensity and time consumption increase

Engineering Contradiction:

Improveassembly qualityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Manual dexterity and skill are replaced with automated equipment that applies controlled thermal energy and mechanical forces. The system uses heating elements to soften wax and robotic mechanisms to position and join sections, replicating and enhancing the precision of skilled artisans while dramatically reducing assembly time and labor requirements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated assembly system incorporates feedback mechanisms to monitor temperature, positioning accuracy, and assembly progress. This feedback allows the system to adjust heating parameters and movement sequences in real-time, maintaining assembly quality comparable to skilled artisans while operating continuously at high speed without fatigue or variability.

Inventive Principle:

Principle #23Feedback

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 process reduces labor intensity and allows for the automated assembly of complex wax trees, improving efficiency and accuracy in creating lost wax trees for casting, enabling the use of automated equipment to handle the assembly of wax trees without damaging them.

Implementation Method 1

heating at least one of the disconnected sections to soften either the wax pattern, the wax runner or both, to allow flexing to occur at the softened sections

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS8082972B1System for assembly wax trees using flexible branch

Publication Date: 2011.12.27 MPI INCORPORATED

AI summary

A process for creating a lost wax tree, including the steps of assembling a wax tree having a wax pattern and a wax runner, using automated equipment to flex either the wax tree or the wax pattern to bring disconnected sections into proximity, heating at least one of the disconnected sections, contacting the disconnected sections and then moving the sections slightly away from one another. A process for casting a part including the steps of creating a lost wax tree and where the wax tree is later covered with a mold material and the wax tree is removed to create a mold, the mold is then used to cast a part similar to the wax pattern. A lost wax tree having a wax tree with a wax pattern and a wax runner, automated equipment for flexing, a heating element, and automated equipment for manipulating disconnected sections.