DE102006009320A1 - Computerized monitoring of casting conditions, prepares data sets concerning individual cores, core assembly and process parameters, to compute molding identifier and eliminate defects - Google Patents

Abstract

During production, three successive data sets (D1-D3) are prepared. The first concerns the composition (1) of casting cores, serving to distinguish them. The second concerns the cores (3, 6, 7) joined to form a core pack. The third concerns the melt (10) composition and process parameters. After successive storage of all three data sets, the cast molding produced, is given an identifier which is linked by computation with the content of the three data sets. Core data comprises sand type, grain size, moisture, temperature, type of binder, binder composition, core shooting machine and its temperature, and preparation data. The machine labels the core, or this takes place immediately after its production. Core, mold and/or casting is/are labeled by: a laser (4), printing, scratching or needling to a depth of 0.1-0.5 mm. Labeling alternatively raises the surface. The label is alphanumerical, a data matrix code or a barcode. A camera (5) reads the label, sending the results to the appropriate data set. An independent claim IS INCLUDED FOR corresponding equipment.

Description

The The invention relates to a method and a device for monitoring the process conditions in a casting process, wherein casting cores, molds and castings are provided with a label that together recorded and stored with other parameters by computer technology is and starting from the finished casting a statement regarding the in the casting process relevant components, materials and parameters.

For different types Technical applications require castings. Regardless of the specific execution of this Castings (for example, as the main body of a machine tool or as a cylinder block of an internal combustion engine) should be detected which casting cores and molds have been used in the respective manufacturing process. Such Documentation has both for the process security as well a traceability the manufacturing conditions a high priority. Thus, can in addition to a proof in connection with any warranty claims already at the time of manufacture a high quality with low error rate and ensures a quick response to any manufacturing defects become. For example, is the reject rate too high or too high? Produced faulty castings, the founder is prompted, at short notice to determine the cause of the error, at least the financial loss to limit. Any lengthy troubleshooting is costly and should be as far as possible be avoided. If it is found during the inspection of a casting, that a mistake by defective casting cores or casting molds has been caused, the respective error can be quickly turned off by starting from the casting over a documentation of the manufacturing conditions the used casting core or the mold used is detectable.

Out JP 2000-015 395 is a technical solution for marking and identification of casting cores and molds known. Here, on the surface of a casting core is first a from a sequence of numbers or from a combination of numbers and Letters existing marking applied with a laser beam. At every casting process This labeling is combined with information about the used mold computer-technically recorded in a memory. Thus, a documentation available with a statement which casting core in combination with which casting mold has been used for the production of castings.

In US 4,774,751 describes a method for monitoring casting processes, which also takes into account the sand used for the casting cores or casting molds. Here, the sand quality as well as the surfaces and geometric contours of the casting cores, casting molds and castings are recorded with several scanners or cameras. These parameters are evaluated by computer technology, so that the production process can be regulated promptly depending on the current measured values. Furthermore, the castings are provided with a bar code, which is engraved with a laser beam or by other technical means in the surface. The barcode is computertechnisch recorded in a memory, so that the respective operative connection between casting sand, casting core, casting mold and casting is detectable.

Another method for monitoring the process conditions in the casting process and for identifying castings is out US 5,894,005 known. Here, the geometric contour of a casting mold is first checked using a camera, which is optionally assembled from a plurality of mold and core parts. Thereafter, this mold is provided with an alphanumeric identifier, which is stored together with the associated parameters computer technology. After the casting process, the cast part produced is also provided with a marking which is likewise stored by computer technology. In addition to the identification of the casting mold, further details of the specific casting process are recorded here, such as the date of manufacture, the production time, the melt temperature or the melt composition, so that here too a concrete active connection between the casting conditions and the casting is detectable.

Even though Thus, several technical solutions are already available with which concrete Traced process conditions starting from the finished casting can be persists in this regard Development needs. This is justified In particular, that the quality of the castings due to the very complex procedure in the casting process of many components dependent is. Consequently, the determination of a respective concrete cause of failure often problematic.

task The invention is therefore a technical solution for process monitoring of casting processes create a short-term in the presence of defective castings Determination of this relevant causes.

This task is solved by creating three separate datasets in the manufacturing process in chronological succession, the first dataset comprising information on the material composition of at least one casting core and for its identification, the second dataset being indications for the identification of several The third set of data includes information about the material composition and the process parameters of the melt and wherein after a continuous common storage of these three data sets, the produced casting is provided with a label that is linked by computer technology with the content of the three data sets. In this case, information relating to the type of sand, grain size, sand moisture, sand temperature, type of binder, binder composition, core shooter, temperature of the core shooter and production date can be recorded for the first data set as a parameter of the core substrate.

On the casting cores can in a nuclear shooter or immediately after that a marking is applied. For the Applying such a mark on the casting cores as well also on the molds or castings are, for example, laser processes, embossing processes, Scratching method or needle method suitable, with a corresponding executed Marking preferably with a depth between 0.1 mm and 5.0 mm into the surface is incorporated. Alternatively, it is possible that in each case to the surface contour raised markings are applied. Independent of the specific method of application, the marking can be alphanumeric, numeric, designed as a data matrix code or as a barcode and preferably read by a camera before they supplied to the respective record becomes.

to execution of such a method, a device is suitable, at least two assemblies for introducing markings on the cores and / or molds and / or castings and at least two cameras with which the applied labels are readable. It is in one preferred embodiment according to a core shooter a first laser for marking the casting cores and subsequently a first Camera arranged to read this marking of a casting core. Furthermore, in the field of joining several casting cores into one a mold associated core package a second camera for reading the markings of this several casting cores arranged and after the mold a second laser for marking the castings.

By Application of the technical invention solution becomes a process monitor of casting processes possible, with the presence of faulty castings a short-term determination the one for this relevant causes can be realized. Thus, a fast Statement possible, whether during the casting process defective cores have been used or what other parameters (Melt, etc.) changed Need to become, to a sufficient quality to ensure the castings and thus to be able to keep the reject rate low.

following is an embodiment of Invention described with reference to the drawing, in which the fundamental Structure of a device is shown stylized, with which the proposed Procedure for monitoring the process conditions are realized in a casting process can.

As starting material sand and binder are initially (stylized with reference numerals 1 ) of a core shooter 2 fed, in which a first casting core 3 is produced. On this casting core 3 comes with a first laser 4 an identification applied subsequently with a first camera 5 is read. The marking is changed for each casting core so that each casting core receives an individual marking. The first laser 4 and the first camera 5 are in operative connection with a computer in which based on the laser 4 and the camera 5 transmitted information, a first data set D1 is created. Alternatively to using a camera 5 could be the marking of the casting core 3 also be read by a worker with the eye and entered manually in the computer. The use of a camera 5 However, it is advantageous because subjective errors are avoided and automatic data collection is possible.

In the further manufacturing process, for example, three casting cores 3 . 6 and 7 used. The ones on these foundries 3 . 6 and 7 applied markings are with a second camera 8th before they are put together to form a core package that is a casting mold 9 is assigned. The second camera 8th is also operatively connected to the computer, in which based on the camera 8th transmitted information a second record D2 is created.

The computer will continue to provide information on the material composition and other process parameters of the melt (stylized with reference numerals 10 ) transmitted. Based on this information, a third record D3 is created.

The records D1, D2 and D3 are continuously stored together. The shared memory unit is connected to a second laser 11 in operative connection with the casting 12 an identification is applied. As a result, the marking of the casting is 12 computer-technically linked to the content of the three data sets D1, D2 and D3, so that starting from the finished casting 12 a statement regarding the components, materials and parameters relevant in the casting process becomes possible. Thus, if needed, for example, fast It is determined which casting parameters were present, on which date was cast, which casting cores were used, how old these cores were at the time of their use, what composition the sand had or with which core shooter and at what temperature a particular core was shot , Consequently, by marking, reading, capturing and storing the data according to the invention and by assigning this amount of data to a marking, the casting process becomes more transparent and any necessary troubleshooting by viewing the available data much easier, so that at the same time a high process reliability is ensured.

1

sand and binder

2

Core shooter

3

first casting core

4

first laser

5

first camera

6

second casting core

7

third casting core

8th

second camera

9

mold

10

melt

11

second laser

12

casting

D1

first record

D2

second record

D3

third record

Claims (10)

Method for monitoring the process conditions in a casting process, wherein casting cores, casting molds and castings are provided with a marking, which is captured together with other parameters computer technology and stored and allows starting from the finished casting a statement regarding the relevant in the casting process components, materials and parameters , characterized in that in the manufacturing process temporally successive three separate data sets are created, wherein the first data set includes information on the material composition of at least one casting core and the same, wherein the second set of data for labeling comprises a plurality of core cores assembled together casting cores, the third data set comprises information on the composition of the material and the process parameters of the melt, and wherein after a continuous common storage of these three data sets, the cast part produced has a code number which is computer-technically linked to the content of the three data sets. Method according to claim 1, characterized in that that for the first data set as a parameter of the core substrate Details concerning the type of sand, grain size, sand moisture, Sand temperature, binder type, binder composition, core shooter, temperature the core shooter and the date of manufacture. Method according to claim 1, characterized in that that in the core shooter a marking on the casting cores is applied. Method according to claim 1, characterized in that that immediately after the core shooter labeling on the casting cores is applied. Method according to claim 1, characterized in that that on the casting cores and / or molds and / or castings a marking with a laser process or with a stamping process or with a scratching method or with a needle method each with a depth between 0.1 mm and 5.0 mm is incorporated. Method according to claim 1, characterized in that that on the casting cores and / or molds and / or castings raised to the surface contour marking is applied. Method according to claim 1, characterized in that that the marking of the casting cores and / or molds and / or castings alphanumeric or numeric or as a data matrix code or is designed as a barcode. Method according to claim 1, characterized in that that the marking of the casting cores and / or molds and / or castings read by a camera and from this the supplied to each record becomes. Device for carrying out a method for monitoring the process conditions in a casting process according to one of claims 1 to 8, characterized in that the device comprises at least two assemblies ( 4 ; 11 ) for the introduction of markings on foundry cores ( 3 ; 6 ; 7 ) and / or casting molds ( 9 ) and / or castings ( 12 ) and at least two cameras ( 5 ; 8th ), with which the applied markings are readable. Apparatus according to claim 9, characterized in that after a core shooting machine ( 2 ) a first laser ( 4 ) for identifying a casting core ( 3 ) and subsequently a first camera ( 5 ) to read this mark as well as in the field the assembly of several cores ( 3 ; 6 ; 7 ) to a mold ( 9 ) assigned a second camera ( 8th ) for reading the identifications of these multiple cores ( 3 ; 6 ; 7 ) and after the mold ( 9 ) a second laser ( 11 ) for marking castings ( 12 ) is arranged.