CA2124820A1 - Automated core assembly integrated with metallic core manufacture - Google Patents
Automated core assembly integrated with metallic core manufactureInfo
- Publication number
- CA2124820A1 CA2124820A1 CA002124820A CA2124820A CA2124820A1 CA 2124820 A1 CA2124820 A1 CA 2124820A1 CA 002124820 A CA002124820 A CA 002124820A CA 2124820 A CA2124820 A CA 2124820A CA 2124820 A1 CA2124820 A1 CA 2124820A1
- Authority
- CA
- Canada
- Prior art keywords
- core
- core assembly
- cores
- molten metal
- plastic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
- B22C9/103—Multipart cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
- B22D17/20—Accessories: Details
- B22D17/22—Dies; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies
- B22D17/24—Accessories for locating and holding cores or inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/76—Cores
Abstract
Multiple metallic cores (60) are formed and assembled automatically into an assembly for a plastic injection molded component. In the past, cores have had to be made one at a time and assembled manually. The method comprises the steps of injecting molten metal alloy into at least one core die (18), removing a core from the die by a robotic handler (26) and inserting the core into one of a plurality of locations in a core assembly fixture (30) repeating the steps until the plurality of locations are filled and the core assembly is complete, and removing the complete core assembly for transportation (38) to a plastic molding machine to produce the plastic component. The core assembly is then melted out from the plastic component, and the molten metal alloy produced thereby is returned to a molten metal alloy tank (10).
Description
AUTOlLaTED CORI~ ASSE~LY INTEGRATED ~ITH
~IETALLIC CORE IIANIIFACT~IRE
5 . TECHNICAL FIELD
The present invention relates to melt-out metal core~
for molded pla~tic components. More ~pecifically the present invention relate~ to forming multiple metallic cores into a core assembly for a plastic injection molded component.
BACKGROUND ART
Melt-out metal parts of complex shapes are made for use as core~ in sub-equent molded plastic components. Melt-out metal parts are also used for encapsulating components such as turbine blades 80 they may be held for machining and other finishing steps. On many application~ using m~lt-out cores~ and encapsulations it iF necessary to engineer the required internal geometry of the finished pla~tic component by u~ing~a plurality of metaIlic cores which are ~preas-embled prior to 1oading the multiple core a~sembly into;~th~e~ plastic injection mold of a plastic molding machîne. It ha8 been necessary in the past to manually assemble each~core into a multiple core 2ssembly and this is both time con~uming and costly.
25 : DISCLOSURE OF INV~NTION
It is an aim of the present invention to provide an auto~atic method and apparatus for producing individual melt-out cores and assembling the metallic cores into a co~mpl-te~core assembly or hold~ng flxture, such as a cassette, which can then be placed in a plastic injection molding machine. By providing an automatic assembly ~ystem, the saving~ in both man power and time is apparent, and WO 93/10954 PCI`/CA91/00422 212~20 furthermore greater accuracy of the core assembly is obtained.
The present invention provides a metallic core injection arrangement such as that shown in U.S. patent No's. 4,958,675 and 5,031,686.` In this patent, melt-out metal cores and the like are made of metal alloys with low melting temperatures and the cores have a high quality finish and a fine grain structure. The cores al30 have high dLmensional accuracy, such being neces~ary to as~emble multi parts within an envelope al80 requiring high accuracy. A
number of die~ are provided 80 that individual core~ can be unloaded manually or by a dedicated robotic ~y~tem that insert~ the cores into a cassette, one or two at a time, to provide a complete core a~embly. The core a~embly is then transported to the plastic moIding machine for the plastic mold to be formed. The holding fixture, which in one embodiment i8 a ca~sette, may remain in the plastic molding machine, or may be removed prior to producing the pla~tic component.
After the plastic component has been formed it i5 placed in an oil melt-out tank which has an oil temperature above the melting temperature of the metallic cores but below the melting temperature of the plastic parts. The metallic material then melts and falls to the bottom of the ~5 tank where it i~ returned to a liquid metal tank for further u~e in producing more individual cores.
The pre~ent invention provides a method of forming ; I multiple metallic core~ into a core as~em~ly for u~e in production of a plastic injection-molded component, said method comprising the steps of a) providing a tank containing molten metal alloy, b) injecting molten metal alloy ~upplied from the molten metal tank into at least one core die, c) removing a aore formed in the core die, and inserting the core into one of a plurality of location~ in a core assembly fixture, d) continuing forming individual WO93/los~ PCT/CA91/0~22 212~20 cores as set forth in steps b - c until all locations of the plurality of locations are filled, and the core assembly is complete, e) transporting the complete core as~embly to a plastic molding machine to produce the plastic component, ,and f) melting the complete core assembly out from the produced plastic component and returning the molten alloy produced thereby to the tank containing molten metal alloy.
The pre~ent invention further provides an apparatus for automatically forming metallic cores into a core assembly for plastic injection molded components, comprising a molten metal tank adapted to contain molten metal, metallic core injection means for injecting molten metal from the molten metal tank at low pre~sure, a plurality of core dies positioned for injection of molten metal from the metallic core injection means, means to remove at least one metal core from at least one of the plurality of core dies and insert the core into one of a plurality of locations in a core assembly fixture, core as~embly indexing means to position the core a~embly fixture so that each of the plurality of locations ha~ a core in~erted therein, robotic removal means to remove a complete core assembly for transportation to a pla~tic injection molding machine, melt-out mean~ adapted to melt metal cores from plastic components, and connection means to return molten metal to the molten metal tank.
In a further embodLment, the pre~ent invention also provides a cassette for forming metallic cores into a core assembly, the cassette having an open position with a plurality of locations adapted to receive individual .....
metallic cores, and having a closed position wherein the cores in the plurality of locations are concentrated to engage with each other and clamped within the cassette, and means to change the cassette from the open position to the closed position to concentrate and clamp the cores into a core assembly.
~.~- ... , , ,, . ~ , . .
WO 93/10954 2 12 ~ ~ 2 0 PCI/CA91/0042?
BRIEF DESCRIPTION OF DRAWINGS
In drawings which illuætrate embodLments of the invention;
Figure 1 i8 a schematic plan view showing one embodiment of an apparatus for automatically assembling cores into a core assembly.
Figure 2 is the front view of a metallic core segment for producing a fluid flywheel or turbine rotor with a melt-out piece.
Figure 3 is a ~ide view of the metallic core segment shown in Figure 2.
Figure 4 i~ a schematic plan view showing another embodiment of an apparatus for automatically assembling cores into a core ass~mhly.
. 15 Figure 5 is a schematic cro~s-sectional view taken at line 5-5 of Figure 4.
Figure 6 is a partial plan view showing a cassette according to one embodiment of the present invention in an open position for loading the metallic cores shown in Figure 2.
Figure 7 is a partial plan view showing the ca~sette of Figure 6 in a closed position with the metallic core~ aoncentrated together ready for insertion into a plastic molding machine.
Figure 8 is a partial plan view showing the ca~sette of Figure 6 indicating sliding segments to move the metallic cores from the open position to the closed position.
Wo 93/10954 pcr/cAsl/oo422 Figure 9 is a sectional view taken at line 9-9 of Figure 8.
Figure 10 is a schematic plan view showing the ,movement of the sliding segments illustrated in Figure 8.
5 MODE:S FOR CARRYTNG OUT THE INVENTION
Ref erring now to Figure 1, a liquid metal tank 10 is shown to contain a molten metal alloy used for melt-out metallic cores. A piston and cylinder 12 within the tank 10 i8 de~igned to force metal alloy through a dispensing arrangement 14 through two nozzle outlets 16 both of which are connested to dies 18 positioned on a rotating indexing table 20. Each die 18 is arranged to produce two core~ 22.
After injection of the core~ 22, the table 20 indexes the dies 18 to a first cooling position and empty dies 18 are rotated to the injection position. There are two a~sembly lines fed from the dispenser 14 and the rotating table~ 20 - index the dies 18 through two cooling positions to an outlet position 24. There are a total of four set of dies 18 arranged around the rotating table 20. Whereas four are ~hown here it will be obvious to those ~killed in the art that more or less may be provided as required.
When in the unloading position 24, two robot arms 26 are arranged at predetermined distance apart to advance, pickup the two cores 22 from the dies 18, bring them back from the dies and the robot 28 rotates through 90, the two arms 26 pivot inward~ 80 the two cores 22 are positioned exactly the correct distance apart, the arms 20 then advance . ..
and insert the cores 22 directly into a cassette 30 to retain them. The cassette 30 forms the cores 22 into a core as~embly. In some embodiments, the cassette 30 is a 3eparate unit which is placed in position prior to insertion of the cores 22. In another embodlment, no cas~ette is needed and the cores 22 are formed to lock together so that when the core a~sembly is complete it holds together as a : :
WO93/l09~ 212 ~ 8 2 0 pcT/cAsl/oo422 unit. Each core assembly 30 is mounted on an indexing table 32 and as shown in the drawings at least two core a~emblie~
are mounted on the indexing table 32. The core as~embly 30 is rotated in the loading position, after each insertion of ,two cores 22 by the robot arms 26. When the cassette 30 i~
full or complete, then it is indexed to the unloading position on the indexing table 32, and a ~econd robot arm 34 picks up the complete core assembly 30 and the robot 36 rotates to drop the core as~embly 30 on a conveyor 38.
The c~mplete core assembly 30 i8 then conveyed to a plastic injection molding machine (not ~hown) placed in the die of the molding machine and the injection molding made.
After cooling the plastic molding is placed on a conveyor 40 as shown in the top of Figure 1 and past through a hot oil tank 42 which ha~ a temperature higher than the melting temperature of the metal but below the melting temperature of the plastic. The metal cores melt and molten metal drops to the bottom of the tank 42. There is a connection at the bottom of the tank 42 80 the molten metal is then transferred to the molten metal tank 10 for reuse. Thi~
permits continuous production of cores ready for assembly.
In one embodiment the molten metal injection dispenæer 14 produces a continuous production cycle of four cores 22 eve~y fifteen seconds. There are twenty-three cores 22 that fit in each core as~embly 30 and it is arranged that on the twelfth injection of molten metal into the dies 18, only one core 22 is filled, thus the twenty-third core is positioned on its own into the core assembly or cassette 30.
The metallic core 22 in one embodiment is a ~egment 60 of a turbine rotor such as that shown in Figures 2 and 3.
Twenty-three ~egment~ 60 of the rotor are assembled in a cassette 30 and then the complete core a~embly is loaded into the die in the plastic injection molding machine, the space between each core segment 60 is filled with plastic to provide a complex three dimensional shape representing a WO 93/10954 212 ~ 8 2 a PCI'/CA91/00422 - 7 - ~:
fluid flywheel er turbine rotor. Such a complex shape is only possible to be molded in one piece by means of a melt-out system.
In the embodiment shown in Figure 1, with two injection stations form four cores at each injection stroke. A cycle tLme of fifteen seconds produce~ sixteen cores per minute which results in a core assembly containing twenty-three cores being assembled in 1.44 minutes.
Another embodiment i5 shown in Figures 4 and 5 wherein four piston~ and cylinders 62 are positioned over a single molten metal tank 64. A transfer line 66 from each cylinder 62 di~pen~es metal alloy through a nozzle outlet 68 to a die 70 to produce at least one core 22. A piston and cylinder 72 opens and closes the die 70.
As seen in Figures 4 and 5, an in~ulated return pipe 74 returns molten metal from a hot oil tank, ~imilar to that shown in Figure 1 to the liquid metal tank 64. A walkway 76 i8 shown beside the tank 64 with an electrical control cabinet 78 on the other ~ide of the walkway 76.
.
Two robotic carriages 80 travel horizontally across the four dies 70 on rails 82 supported by posts 84. The carriages 80 have two piston and cylinders 86 with arms 88 to pick up cores from the dies 70. The carriages 80 are ~hown having two robot arms 88 spaced apart to pick up two core~ from adjacent dies 70. The carriages 80 may pick up one or two cores from each die depending on the requirements. In other embodiment~ two or more core~ may be formed in each die, and the robot arms 88 may pick up the output from two die~ 70 at the same time. Travel of the carriages 80 and the robot arms 88 i8 preferably programmable for different sizes and types of cores being made. Furthermore, whereas piston and cylinder 86 operàting mechanism i8 illustrated, other types of mechanical or electro-mechanical operating mechanisms may be used.
WO93/l0954 212 ~ 8 ~ O --8-- PCI'/CA91/00422 In the embodiment shown in Figures 4 and 5, the robot arms 88 may pick up cores that have hardened in one set of dies 70 while the cores in another set of dies is hardening.
The machine can inject metal alloy into one set of dies, immediately after removing cores. In this way a reduction in cycle time occurs allowing more dies to be produced.
Whereac two sets of dies 70 per robot arm 88 i8 shown, more than two ~ets of dies may be provided dependent upon the production requirements and the hardening times for cores.
Ca~ettes 30 are shown positioned on conveyor~ 90 on either ends of the rails 82 and the robot arms 88 are arranged to in~tall a core into an empty slot in each cas~ette 30. The cassette 30 may be indexed to rotate 80 that the robot arm 88 always loads an empty slot at one location, or the robot arm 88 is arranged to load each slot without the cassette moving, or only moving on the conveyor 90 .
Whereas two robot arms 88 are de~cribed herein, it will be apparent that a single robot arrangement may be de~igned to pick the core directly out of the die 70 and insert it into the cassette 30. The robot arms 88 may pick up one core at a time or multiple cores for insertion into slots in the ca~ette.
A cas~ette 30 suitable for forming a core as~embly is shown in Figures 6 to 9. The cassette 30 has a ba~e plate 94 onto which the cores 60 (as shown in Figures 2 and 3) are inserted. Figure 6 shows the cassette 30 in an open ; position with space around each of the cores 60 so they do not interfere with each other when loaded. Figure 7 illustrate~ the cores 60 pushed inwards and concentrated into a closed position. In this closed position, the cores 60 interlock and in some cases hold them~elves together 80 that the core assembly may be lifted out of the cassette 30 for insertion into the plastic molding machine. In other W093/109~ PCT/CA91/00422 g cases the cores 60 are held in the closed position within the cassette, and the cassette 30 used to position the core assembly in the plastic molding machine. The ca~sette 30 may in some cases be removed after the core a~embly is placed in the plastic molding machine, and in other cases may remain in the plastic molding machine when the plastic component is made. The cassette is generally removed-after this and before the metallic cores are melted out of the plastic component.
Sliding segments 96 are shown in Figures 8, 9 and 10 which each have a keeper plate 98 that fits into slot 100 in the base plate 94. The sliding segments 96 when in the open po~ition allow~ the core~ 60 to be placed onto the ba~e plate. When the required number of cores 60 have been in~erted an actuator 102 pushes each segment 96 inwards and spring detent balls 104 locate the segments 90 in the closed position. Sloped edges are provided on the segment 96 and at the centre portion 106 of the base plate 80 the core~ 60 are locked in place, and furthermore in one embodiment the cores 60 themselves lock together, so once all the segment~
96 are pushed into the centre to form the closed position, the~segments 96 may be withdrawn, the centre portion 106 of the base plate is lifted out, and the core a~sembly is then free to be removed for insertion in a plastic molding machine.
.
Figure 10 illustrates movement of the ~egments 96 from the open position to the closed position.
Various changes may be made to the embodiments shown herein ~ithout departing form the scope of the pre~ent invention which is limited only by the following claims.
~IETALLIC CORE IIANIIFACT~IRE
5 . TECHNICAL FIELD
The present invention relates to melt-out metal core~
for molded pla~tic components. More ~pecifically the present invention relate~ to forming multiple metallic cores into a core assembly for a plastic injection molded component.
BACKGROUND ART
Melt-out metal parts of complex shapes are made for use as core~ in sub-equent molded plastic components. Melt-out metal parts are also used for encapsulating components such as turbine blades 80 they may be held for machining and other finishing steps. On many application~ using m~lt-out cores~ and encapsulations it iF necessary to engineer the required internal geometry of the finished pla~tic component by u~ing~a plurality of metaIlic cores which are ~preas-embled prior to 1oading the multiple core a~sembly into;~th~e~ plastic injection mold of a plastic molding machîne. It ha8 been necessary in the past to manually assemble each~core into a multiple core 2ssembly and this is both time con~uming and costly.
25 : DISCLOSURE OF INV~NTION
It is an aim of the present invention to provide an auto~atic method and apparatus for producing individual melt-out cores and assembling the metallic cores into a co~mpl-te~core assembly or hold~ng flxture, such as a cassette, which can then be placed in a plastic injection molding machine. By providing an automatic assembly ~ystem, the saving~ in both man power and time is apparent, and WO 93/10954 PCI`/CA91/00422 212~20 furthermore greater accuracy of the core assembly is obtained.
The present invention provides a metallic core injection arrangement such as that shown in U.S. patent No's. 4,958,675 and 5,031,686.` In this patent, melt-out metal cores and the like are made of metal alloys with low melting temperatures and the cores have a high quality finish and a fine grain structure. The cores al30 have high dLmensional accuracy, such being neces~ary to as~emble multi parts within an envelope al80 requiring high accuracy. A
number of die~ are provided 80 that individual core~ can be unloaded manually or by a dedicated robotic ~y~tem that insert~ the cores into a cassette, one or two at a time, to provide a complete core a~embly. The core a~embly is then transported to the plastic moIding machine for the plastic mold to be formed. The holding fixture, which in one embodiment i8 a ca~sette, may remain in the plastic molding machine, or may be removed prior to producing the pla~tic component.
After the plastic component has been formed it i5 placed in an oil melt-out tank which has an oil temperature above the melting temperature of the metallic cores but below the melting temperature of the plastic parts. The metallic material then melts and falls to the bottom of the ~5 tank where it i~ returned to a liquid metal tank for further u~e in producing more individual cores.
The pre~ent invention provides a method of forming ; I multiple metallic core~ into a core as~em~ly for u~e in production of a plastic injection-molded component, said method comprising the steps of a) providing a tank containing molten metal alloy, b) injecting molten metal alloy ~upplied from the molten metal tank into at least one core die, c) removing a aore formed in the core die, and inserting the core into one of a plurality of location~ in a core assembly fixture, d) continuing forming individual WO93/los~ PCT/CA91/0~22 212~20 cores as set forth in steps b - c until all locations of the plurality of locations are filled, and the core assembly is complete, e) transporting the complete core as~embly to a plastic molding machine to produce the plastic component, ,and f) melting the complete core assembly out from the produced plastic component and returning the molten alloy produced thereby to the tank containing molten metal alloy.
The pre~ent invention further provides an apparatus for automatically forming metallic cores into a core assembly for plastic injection molded components, comprising a molten metal tank adapted to contain molten metal, metallic core injection means for injecting molten metal from the molten metal tank at low pre~sure, a plurality of core dies positioned for injection of molten metal from the metallic core injection means, means to remove at least one metal core from at least one of the plurality of core dies and insert the core into one of a plurality of locations in a core assembly fixture, core as~embly indexing means to position the core a~embly fixture so that each of the plurality of locations ha~ a core in~erted therein, robotic removal means to remove a complete core assembly for transportation to a pla~tic injection molding machine, melt-out mean~ adapted to melt metal cores from plastic components, and connection means to return molten metal to the molten metal tank.
In a further embodLment, the pre~ent invention also provides a cassette for forming metallic cores into a core assembly, the cassette having an open position with a plurality of locations adapted to receive individual .....
metallic cores, and having a closed position wherein the cores in the plurality of locations are concentrated to engage with each other and clamped within the cassette, and means to change the cassette from the open position to the closed position to concentrate and clamp the cores into a core assembly.
~.~- ... , , ,, . ~ , . .
WO 93/10954 2 12 ~ ~ 2 0 PCI/CA91/0042?
BRIEF DESCRIPTION OF DRAWINGS
In drawings which illuætrate embodLments of the invention;
Figure 1 i8 a schematic plan view showing one embodiment of an apparatus for automatically assembling cores into a core assembly.
Figure 2 is the front view of a metallic core segment for producing a fluid flywheel or turbine rotor with a melt-out piece.
Figure 3 is a ~ide view of the metallic core segment shown in Figure 2.
Figure 4 i~ a schematic plan view showing another embodiment of an apparatus for automatically assembling cores into a core ass~mhly.
. 15 Figure 5 is a schematic cro~s-sectional view taken at line 5-5 of Figure 4.
Figure 6 is a partial plan view showing a cassette according to one embodiment of the present invention in an open position for loading the metallic cores shown in Figure 2.
Figure 7 is a partial plan view showing the ca~sette of Figure 6 in a closed position with the metallic core~ aoncentrated together ready for insertion into a plastic molding machine.
Figure 8 is a partial plan view showing the ca~sette of Figure 6 indicating sliding segments to move the metallic cores from the open position to the closed position.
Wo 93/10954 pcr/cAsl/oo422 Figure 9 is a sectional view taken at line 9-9 of Figure 8.
Figure 10 is a schematic plan view showing the ,movement of the sliding segments illustrated in Figure 8.
5 MODE:S FOR CARRYTNG OUT THE INVENTION
Ref erring now to Figure 1, a liquid metal tank 10 is shown to contain a molten metal alloy used for melt-out metallic cores. A piston and cylinder 12 within the tank 10 i8 de~igned to force metal alloy through a dispensing arrangement 14 through two nozzle outlets 16 both of which are connested to dies 18 positioned on a rotating indexing table 20. Each die 18 is arranged to produce two core~ 22.
After injection of the core~ 22, the table 20 indexes the dies 18 to a first cooling position and empty dies 18 are rotated to the injection position. There are two a~sembly lines fed from the dispenser 14 and the rotating table~ 20 - index the dies 18 through two cooling positions to an outlet position 24. There are a total of four set of dies 18 arranged around the rotating table 20. Whereas four are ~hown here it will be obvious to those ~killed in the art that more or less may be provided as required.
When in the unloading position 24, two robot arms 26 are arranged at predetermined distance apart to advance, pickup the two cores 22 from the dies 18, bring them back from the dies and the robot 28 rotates through 90, the two arms 26 pivot inward~ 80 the two cores 22 are positioned exactly the correct distance apart, the arms 20 then advance . ..
and insert the cores 22 directly into a cassette 30 to retain them. The cassette 30 forms the cores 22 into a core as~embly. In some embodiments, the cassette 30 is a 3eparate unit which is placed in position prior to insertion of the cores 22. In another embodlment, no cas~ette is needed and the cores 22 are formed to lock together so that when the core a~sembly is complete it holds together as a : :
WO93/l09~ 212 ~ 8 2 0 pcT/cAsl/oo422 unit. Each core assembly 30 is mounted on an indexing table 32 and as shown in the drawings at least two core a~emblie~
are mounted on the indexing table 32. The core as~embly 30 is rotated in the loading position, after each insertion of ,two cores 22 by the robot arms 26. When the cassette 30 i~
full or complete, then it is indexed to the unloading position on the indexing table 32, and a ~econd robot arm 34 picks up the complete core assembly 30 and the robot 36 rotates to drop the core as~embly 30 on a conveyor 38.
The c~mplete core assembly 30 i8 then conveyed to a plastic injection molding machine (not ~hown) placed in the die of the molding machine and the injection molding made.
After cooling the plastic molding is placed on a conveyor 40 as shown in the top of Figure 1 and past through a hot oil tank 42 which ha~ a temperature higher than the melting temperature of the metal but below the melting temperature of the plastic. The metal cores melt and molten metal drops to the bottom of the tank 42. There is a connection at the bottom of the tank 42 80 the molten metal is then transferred to the molten metal tank 10 for reuse. Thi~
permits continuous production of cores ready for assembly.
In one embodiment the molten metal injection dispenæer 14 produces a continuous production cycle of four cores 22 eve~y fifteen seconds. There are twenty-three cores 22 that fit in each core as~embly 30 and it is arranged that on the twelfth injection of molten metal into the dies 18, only one core 22 is filled, thus the twenty-third core is positioned on its own into the core assembly or cassette 30.
The metallic core 22 in one embodiment is a ~egment 60 of a turbine rotor such as that shown in Figures 2 and 3.
Twenty-three ~egment~ 60 of the rotor are assembled in a cassette 30 and then the complete core a~embly is loaded into the die in the plastic injection molding machine, the space between each core segment 60 is filled with plastic to provide a complex three dimensional shape representing a WO 93/10954 212 ~ 8 2 a PCI'/CA91/00422 - 7 - ~:
fluid flywheel er turbine rotor. Such a complex shape is only possible to be molded in one piece by means of a melt-out system.
In the embodiment shown in Figure 1, with two injection stations form four cores at each injection stroke. A cycle tLme of fifteen seconds produce~ sixteen cores per minute which results in a core assembly containing twenty-three cores being assembled in 1.44 minutes.
Another embodiment i5 shown in Figures 4 and 5 wherein four piston~ and cylinders 62 are positioned over a single molten metal tank 64. A transfer line 66 from each cylinder 62 di~pen~es metal alloy through a nozzle outlet 68 to a die 70 to produce at least one core 22. A piston and cylinder 72 opens and closes the die 70.
As seen in Figures 4 and 5, an in~ulated return pipe 74 returns molten metal from a hot oil tank, ~imilar to that shown in Figure 1 to the liquid metal tank 64. A walkway 76 i8 shown beside the tank 64 with an electrical control cabinet 78 on the other ~ide of the walkway 76.
.
Two robotic carriages 80 travel horizontally across the four dies 70 on rails 82 supported by posts 84. The carriages 80 have two piston and cylinders 86 with arms 88 to pick up cores from the dies 70. The carriages 80 are ~hown having two robot arms 88 spaced apart to pick up two core~ from adjacent dies 70. The carriages 80 may pick up one or two cores from each die depending on the requirements. In other embodiment~ two or more core~ may be formed in each die, and the robot arms 88 may pick up the output from two die~ 70 at the same time. Travel of the carriages 80 and the robot arms 88 i8 preferably programmable for different sizes and types of cores being made. Furthermore, whereas piston and cylinder 86 operàting mechanism i8 illustrated, other types of mechanical or electro-mechanical operating mechanisms may be used.
WO93/l0954 212 ~ 8 ~ O --8-- PCI'/CA91/00422 In the embodiment shown in Figures 4 and 5, the robot arms 88 may pick up cores that have hardened in one set of dies 70 while the cores in another set of dies is hardening.
The machine can inject metal alloy into one set of dies, immediately after removing cores. In this way a reduction in cycle time occurs allowing more dies to be produced.
Whereac two sets of dies 70 per robot arm 88 i8 shown, more than two ~ets of dies may be provided dependent upon the production requirements and the hardening times for cores.
Ca~ettes 30 are shown positioned on conveyor~ 90 on either ends of the rails 82 and the robot arms 88 are arranged to in~tall a core into an empty slot in each cas~ette 30. The cassette 30 may be indexed to rotate 80 that the robot arm 88 always loads an empty slot at one location, or the robot arm 88 is arranged to load each slot without the cassette moving, or only moving on the conveyor 90 .
Whereas two robot arms 88 are de~cribed herein, it will be apparent that a single robot arrangement may be de~igned to pick the core directly out of the die 70 and insert it into the cassette 30. The robot arms 88 may pick up one core at a time or multiple cores for insertion into slots in the ca~ette.
A cas~ette 30 suitable for forming a core as~embly is shown in Figures 6 to 9. The cassette 30 has a ba~e plate 94 onto which the cores 60 (as shown in Figures 2 and 3) are inserted. Figure 6 shows the cassette 30 in an open ; position with space around each of the cores 60 so they do not interfere with each other when loaded. Figure 7 illustrate~ the cores 60 pushed inwards and concentrated into a closed position. In this closed position, the cores 60 interlock and in some cases hold them~elves together 80 that the core assembly may be lifted out of the cassette 30 for insertion into the plastic molding machine. In other W093/109~ PCT/CA91/00422 g cases the cores 60 are held in the closed position within the cassette, and the cassette 30 used to position the core assembly in the plastic molding machine. The ca~sette 30 may in some cases be removed after the core a~embly is placed in the plastic molding machine, and in other cases may remain in the plastic molding machine when the plastic component is made. The cassette is generally removed-after this and before the metallic cores are melted out of the plastic component.
Sliding segments 96 are shown in Figures 8, 9 and 10 which each have a keeper plate 98 that fits into slot 100 in the base plate 94. The sliding segments 96 when in the open po~ition allow~ the core~ 60 to be placed onto the ba~e plate. When the required number of cores 60 have been in~erted an actuator 102 pushes each segment 96 inwards and spring detent balls 104 locate the segments 90 in the closed position. Sloped edges are provided on the segment 96 and at the centre portion 106 of the base plate 80 the core~ 60 are locked in place, and furthermore in one embodiment the cores 60 themselves lock together, so once all the segment~
96 are pushed into the centre to form the closed position, the~segments 96 may be withdrawn, the centre portion 106 of the base plate is lifted out, and the core a~sembly is then free to be removed for insertion in a plastic molding machine.
.
Figure 10 illustrates movement of the ~egments 96 from the open position to the closed position.
Various changes may be made to the embodiments shown herein ~ithout departing form the scope of the pre~ent invention which is limited only by the following claims.
Claims (9)
1. A method of forming multiple metallic cores (22) into a core assembly (30) for use in production of a plastic injection-molded component, said method comprising the steps of:
a) providing a tank (10) containing molten metal alloy, b) injecting molten metal alloy supplied from the molten metal tank (10) into a least one core die (18) located at a fill stage of an indexing means (20), c) indexing the core die (18) through a cooling stage to an unloading stage (24), d) removing a core (22) formed in the core die (18), and inserting the core (22) into one of a plurality of locations in the core assembly (30), e) continuing forming individual cores (18) as set forth in steps b-d until all locations of the plurality of locations are filled, and the core assembly (30) is complete, f) transporting the complete core assembly (30) to a plastic molding machine to produce the plastic component, and g) melting the core assembly (30) out from the produced plastic component in hot oil and returning the molten alloy produced thereby to the tank (10) containing molten metal alloy.
a) providing a tank (10) containing molten metal alloy, b) injecting molten metal alloy supplied from the molten metal tank (10) into a least one core die (18) located at a fill stage of an indexing means (20), c) indexing the core die (18) through a cooling stage to an unloading stage (24), d) removing a core (22) formed in the core die (18), and inserting the core (22) into one of a plurality of locations in the core assembly (30), e) continuing forming individual cores (18) as set forth in steps b-d until all locations of the plurality of locations are filled, and the core assembly (30) is complete, f) transporting the complete core assembly (30) to a plastic molding machine to produce the plastic component, and g) melting the core assembly (30) out from the produced plastic component in hot oil and returning the molten alloy produced thereby to the tank (10) containing molten metal alloy.
2. The method of forming multiple metallic cores (22) according to claim 1 wherein the core assembly (30) is rotated a predetermined angular displacement between each insertion of a core (22).
3. The method of forming multiple metallic cores (22) according to claim 1 or claim 2 wherein the core (22) is removed from the core die (18) and inserted into one of a plurality of locations in the core assembly (30) by robotic handling means (28).
4. An apparatus for automatically forming metallic cores (22) into a core assembly (30) for plastic injection molded components comprising:
a molten metal tank (10) adapted to contain molten metal, metallic core injection-means (14) for injecting molten metal from the molten metal tank (10) at low pressure into at least one of a plurality of core dies (18) located at a fill stage for injection of molten metal, die indexing means (20) for indexing the core dies (18) from the fill stage through a cooling stage to a removal stage (24), means to remove at least one metal core (22) from at least one of the plurality of core dies (18) at the removal stage (24) and insert the core (22) into one of a plurality of locations in a core assembly fixture (30), core assembly indexing means (32) to position the core assembly (30) so that each of the plurality of locations has a core (22) inserted therein, robotic removal means (36) to remove a complete core assembly (30) for transportation to a plastic injection molding machine, melt-out means (42) adapted to melt metal cores (22) from plastic components, and connection means (74) to return molten metal to the molten metal tank (10).
a molten metal tank (10) adapted to contain molten metal, metallic core injection-means (14) for injecting molten metal from the molten metal tank (10) at low pressure into at least one of a plurality of core dies (18) located at a fill stage for injection of molten metal, die indexing means (20) for indexing the core dies (18) from the fill stage through a cooling stage to a removal stage (24), means to remove at least one metal core (22) from at least one of the plurality of core dies (18) at the removal stage (24) and insert the core (22) into one of a plurality of locations in a core assembly fixture (30), core assembly indexing means (32) to position the core assembly (30) so that each of the plurality of locations has a core (22) inserted therein, robotic removal means (36) to remove a complete core assembly (30) for transportation to a plastic injection molding machine, melt-out means (42) adapted to melt metal cores (22) from plastic components, and connection means (74) to return molten metal to the molten metal tank (10).
5. The apparatus for forming metallic cores (22) into a core assembly (30) according to claim 4 wherein the melt-out means (42) comprises an oil melt-out tank (10).
6. The apparatus for forming metallic cores (22) into a core assembly (30) according to claim 4 or claim 5 wherein the core assembly (30) comprises a cassette with an open position for insertion of cores (22) and a closed position for compacting and gripping the cores (22) in the cassette and including means for changing from the open position to the closed position.
7. The apparatus for automatically forming metallic cores (22) into a core assembly (30) according to any of Claims 4 to 6 wherein the core assembly indexing means (32) comprises a rotating table which rotates through a predetermined angle between insertion of cores (22).
8. The apparatus for automatically forming metallic cores (22) into a core assembly (30) according to Claim 7 wherein the rotating table (32) indexes to an unloading position when the core assembly (30) is complete.
9. The apparatus for automatically forming metallic cores (22) into a core assembly (30) according to any of Claims 4 to 8 wherein two core dies (18) are filled with one injection of molten metal.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002124820A CA2124820A1 (en) | 1991-12-02 | 1991-12-02 | Automated core assembly integrated with metallic core manufacture |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002124820A CA2124820A1 (en) | 1991-12-02 | 1991-12-02 | Automated core assembly integrated with metallic core manufacture |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2124820A1 true CA2124820A1 (en) | 1993-06-10 |
Family
ID=4153710
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002124820A Abandoned CA2124820A1 (en) | 1991-12-02 | 1991-12-02 | Automated core assembly integrated with metallic core manufacture |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2124820A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109397618A (en) * | 2018-12-07 | 2019-03-01 | 江苏元泰智能科技股份有限公司 | A kind of cooperation injection molding machine combined type mode enters sub full-automatic loading and unloading and dismantling mechanism |
-
1991
- 1991-12-02 CA CA002124820A patent/CA2124820A1/en not_active Abandoned
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109397618A (en) * | 2018-12-07 | 2019-03-01 | 江苏元泰智能科技股份有限公司 | A kind of cooperation injection molding machine combined type mode enters sub full-automatic loading and unloading and dismantling mechanism |
| CN109397618B (en) * | 2018-12-07 | 2024-01-05 | 江苏元泰智能科技股份有限公司 | Full-automatic feeding and discharging and disassembling mechanism matched with combined type mold insert of injection molding machine |
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| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |