JP2011206788A - Casting condition determination method and determination device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a casting condition determination method for a die casting machine which reduces the load of analysis performed per product or die and can set casting conditions obtainable of an excellent article in a short time even by an operator whose degree of skill is low, and a determination device therefor.SOLUTION: In the setting of the casting conditions for a die casting machine, excellent article casting conditions or defective article casting conditions utilizing CAE, obtained from the molten metal behavior analysis result within a plunger sleeve from molten metal supply to injection are beforehand stored in a casting condition storage part as a data base, the set values of a plurality of set items composing the casting conditions of the die casting machine are inputted, and are displayed as input set values, further, the input set values are compared with the data base stored in the casting condition storage part by a casting condition comparison part, and warning is emitted to the input set values not suited to the excellent article casting conditions or the input set values suited to the defective article casting conditions.

Description

  The present invention relates to a casting condition determination method and determination apparatus in setting of casting conditions for a die casting machine.

  In casting using a die casting machine, in order to obtain a good product, the amount of hot water (casting weight), injection low speed, injection high speed, injection speed switching position, pressurization time, casting pressure, mold clamping force, various timer values, etc. It is necessary to appropriately input and set casting conditions composed of a plurality of setting items to a die casting machine.

  Conventionally, setting of these casting conditions to the die casting machine is presumed to be possible to solve the cause of defects in the casting conditions by actually casting and checking the product based on the casting conditions set by the operator for the time being at the casting site. The setting value of the setting item to be set or the setting value of the setting item that is presumed to obtain a better product is input again, and then the casting is performed again to check the product. Therefore, there is a problem that it takes time to set casting conditions for obtaining a good product corresponding to one product or mold. In addition, checking the cast product and determining how much and what items of casting conditions are changed, and what kind of situation is improved and a good product can be obtained, largely depends on the experience and intuition of the worker. If the skilled person is low in skill, it takes a lot of time to set the casting conditions to obtain good products, or the casting conditions that meet the required quality of the product cannot be set due to time constraints. Even so, there is a problem that the yield rate is not increased and the manufacturing cost of the product is increased.

  In Patent Document 1, various types of known data such as mold data and product data are input by a data input unit using a man-machine interface, and various types of mold data and product data are input by a casting condition calculation unit by the data input unit. A casting condition setting device that calculates casting condition values by a predetermined calculation formula, and various casting condition values are displayed on the screen display unit and automatically set as casting condition values in the die casting machine in the casting condition setting unit. It is disclosed.

JP-A-10-58115

  According to the casting condition setting device of Patent Document 1, various casting condition values are calculated from various known data such as mold data and product data input by an operator from a data input unit using a predefined calculation formula. Is calculated by the casting condition calculation unit, and the calculated various casting conditions are automatically set by the casting condition setting unit. In addition, the pre-defined calculation formula includes a correction term coefficient set with parameters, and the user's own rule of thumb and know-how can be added to the calculation formula. Further, the casting condition setting value can be changed by the man-machine interface unit, and the changed casting condition setting value is compared with the casting condition setting value calculated by the casting condition calculation unit. A casting condition set value suitability determining unit that outputs an alarm when the condition value differs by a predetermined value or more is provided.

  However, the casting condition setting device of Patent Document 1 stores in advance a calculation formula that can be easily calculated by a scientific calculator or a spreadsheet software of a personal computer in a calculation formula data memory, and these calculation formulas based on input values. It merely automates the calculation of various casting condition values according to, and the input and setting of the calculated values obtained by the calculation to the die casting machine. In addition, a correction term coefficient set as a parameter is included in the predefined calculation formula, and it is supposed that each user's own rule of thumb and know-how can be added to the calculation formula. However, the correction term coefficient for adding the user's own empirical rules and know-how to the calculation formula is merely multiplied by the calculation formula for obtaining various casting condition values, and thus has only an effect of increasing or decreasing each calculation value. In addition, it is difficult to accurately add the user's own rules of thumb and know-how related to the setting items related to each other, such as various known data and calculated values calculated from the known data, to the casting conditions. I must say that there is.

  Further, when the casting condition setting value is changed by the operator, the changed casting condition setting value is compared with the casting condition value calculated by the casting condition calculation unit, and the changed casting condition setting value is the casting condition value. In contrast, it has a casting condition set value suitability determining unit that outputs an alarm when the difference is more than a predetermined value. However, in a product or a mold to be cast for the first time, in the state where there is no casting condition setting value to be compared, it is not possible to output an alarm when the change of the casting condition setting value is not appropriate. Before that, it is judged whether the various known data input as casting conditions are appropriate in the specifications of the die casting machine, and these various known data and the calculated values calculated from the known data are in light of the user's own rules of thumb and know-how. It is not possible to judge whether it is appropriate. In addition, information such as a recommended value or a proper value regarding a newly input set value cannot be provided to the worker.

  In addition, as described above, in the casting condition setting apparatus of Patent Document 1, the die thickness, product thickness, product weight, casting weight, projected area, gate cross-sectional area, plunger tip diameter, filling stroke, idle driving Various casting condition values are calculated from predefined data such as stroke and biscuit thickness, and these casting condition values are automatically set in the die casting machine. However, since these casting condition values are calculated according to a predefined calculation formula, it is difficult to calculate with the calculation formula, analysis of the molten metal behavior in the plunger sleeve from hot water supply to injection, and the molten metal ( Various product failure factors that occur in the plunger sleeve and in the mold can only be predicted from the analysis of the molten metal behavior when molten metal is filled and the analysis of the molten metal solidification in the mold after filling. It cannot be avoided. Therefore, the casting condition automatically set by the casting condition setting device of Patent Document 1 cannot be a casting condition for obtaining a non-defective product even if it is a casting condition capable of casting. Based on the casting conditions calculated from the data, the actual casting is performed to confirm the product. Based on the experience and intuition of the operator, the setting values of the setting items that are estimated to be able to solve the failure factors of various casting condition values, or It is necessary to re-enter the setting value of the setting item that is presumed to obtain a better product, and then confirm the product by casting again. In addition, there is no guidance to the operator for logically setting casting conditions without depending on the experience and intuition of the operator.

  As described above, even in the casting condition setting device of Patent Document 1, an operator with a low skill level logically sets casting conditions for new products or molds for which casting conditions are not set. Is difficult, even if the casting conditions are automatically set by the casting condition setting device of Patent Document 1, the operator actually casts the product and confirms the product, and the setting of the casting conditions is estimated to be able to solve the defect factor After re-entering the setting value of the item or the setting value of the setting item that is estimated to obtain a better product, it is still necessary to check the product by casting again, and in that work, There is no guidance to the worker for logically setting the casting conditions without depending on the worker's experience and intuition. Therefore, it is possible to set the casting conditions logically without depending on the experience and intuition of the operator, and at the same time, the time required for setting the casting conditions can be shortened compared to the conventional one, and the operating rate of the die casting machine can be improved. It must be said that it is difficult to achieve the effect described in Patent Document 1.

  Here, in order to reduce the time required for the work for setting the casting conditions capable of obtaining a good product based on the experience and intuition of the operator as described above, analysis of the molten metal behavior in the mold using CAE, A solidification analysis of a product is performed to obtain a casting condition that seems to be appropriate, and setting items and setting values of casting conditions to be corrected are narrowed down. In recent years, due to technological advances in computers and analysis software, it is also possible for casters themselves to perform these analyzes using a general-purpose personal computer and commercially available analysis software without having to request analysis specialists. Therefore, there are some casting sites that are used to set the casting conditions for obtaining good products.

  However, these analyzes require CAD data (drawing data) of the mold, and it is necessary to perform analysis for each product or mold. In other words, a computer usage environment that has been improved to some extent and human resources who have knowledge of both the computer system and casting technology are required. It is difficult to introduce a simple analysis. Furthermore, in recent years, the number of molds has increased due to the production of various small quantities, or the structure of the molds has become more complex. On the other hand, casting has become difficult due to the separation from the casting site and the aging of workers. It is difficult to secure the necessary number of skilled workers. In such a casting site, it is possible to reduce the load of analysis performed for each product or die, and to set casting conditions for obtaining a good product in a short time even for an unskilled worker. There is an urgent need for a casting condition judgment method and a judgment device that can be used.

  The present invention has been made in view of the above-described problems, reduces the load of analysis performed for each product or mold, and can obtain a good product even for an operator having a low skill level. It is an object of the present invention to provide a casting condition determination method and determination apparatus for a die casting machine that can set casting conditions in a short time.

The object of the present invention is to set the casting conditions of the die casting machine as shown in claim 1.
Using the CAE, the good product casting condition or the defective product casting condition obtained from the molten metal behavior analysis result in the plunger sleeve from hot water supply to injection is stored in advance as a database in the casting condition storage unit,
Set values of a plurality of setting items constituting the casting conditions of the die casting machine are input from the casting condition input unit, displayed as input setting values on the casting condition display unit,
The input set value is compared with the database stored in the casting condition storage unit by the casting condition comparison unit,
This is achieved by a casting condition determination method in which a warning is issued with respect to the input set value that does not conform to the non-defective casting condition or the input set value that conforms to the defective casting condition.

  That is, since the database of good casting conditions or defective casting conditions preliminarily stored in the casting condition storage unit is obtained from the molten metal behavior analysis result in the plunger sleeve from hot water supply to injection using CAE, these If the casting conditions are based on the database, it is possible to avoid the occurrence of product failure factors in the plunger sleeve, which cannot be avoided with the casting conditions calculated from the calculation formula. Furthermore, since the input set values are compared with these databases and a warning is issued for inappropriate input set values, even the inexperienced worker has the casting conditions for the first product or mold. Even if it is not set yet, appropriate casting conditions can be set. Furthermore, if the database is configured to include not only good casting conditions but also defective casting conditions, the comparison between the input set value and the database can be performed more reliably.

Furthermore, as shown in claim 2, the database is
In the plunger sleeve confirmed from the molten metal behavior analysis result,
1) The phenomenon of the molten metal climbing to the end of the diverter 2) The phenomenon of the molten metal temperature decreasing to the solidified layer formation temperature at the boundary surface between the plunger sleeve inner wall and the molten metal 3) The phenomenon of the molten metal temperature decreasing to the predetermined temperature 4) The air to the molten metal 5) In the database of non-defective casting conditions or defective casting conditions determined from the judgment criteria for determining the occurrence of at least one of the oxide film forming phenomena on the air contact surface of the molten metal as the occurrence of defective products The casting condition determining method according to claim 1 is preferable.

  In other words, the criteria for determining the occurrence of defective products has been clarified as a phenomenon that occurs in the plunger sleeve, so if the same analysis software is used, the analysis results can be reflected in the non-defective casting conditions or defective casting conditions. It can be done without depending on the experience and competence of the analyst.

Further, as shown in claim 3, the database is either a numerical range defined by a reference value and an upper and lower allowable range relative to the reference value, or a numerical range defined by an upper limit value and a lower limit value. Including the setting items consisting of appropriate values or inappropriate values defined in
Each time one input set value is input, the appropriate value or the inappropriate value of the setting item corresponding to the input set value is selected from the database by the casting condition comparison unit, and the input set value and 3. The casting condition determining method according to claim 1, wherein the casting condition is displayed on the casting condition display unit in a comparable manner.

  The casting conditions include a setting item with a set value that can be selected, such as a plunger sleeve inner diameter, and a setting item in which a set value is arbitrarily selected within a certain numerical range, such as a hot water supply amount. . If it is the former, an input setting value and the appropriate value or the inappropriate value of the setting item corresponding to an input setting value can be compared simultaneously on a casting condition display part. In the latter case, it becomes clear which position the input set value is in the numerical value range of the appropriate value or the inappropriate value of the corresponding setting item. In any case, if the input set value is determined to be an inappropriate value, the appropriate input set value may be re-input while comparing with the appropriate value or inappropriate value corresponding to the displayed input set value. Therefore, appropriate casting conditions can be set. In addition, if the appropriate value or improper value of each setting item in the database is defined within the range defined by the reference value and the allowable range of the upper and lower limits for the reference value, when checking the casting condition display part, The standard value of the casting conditions and the allowable range thereof are clarified. Moreover, if it defines within the range prescribed | regulated by an upper limit and a lower limit, since there are few display items, it will become easy to see a casting condition display part. It is preferable that a user or an operator can appropriately select which definition is used to display each setting item.

  Next, as shown in claim 4, each time one input set value is input, the appropriate value or the inappropriate value of the setting item corresponding to the uninput set value that has not yet been input is stored in the database. Is selected by the casting condition comparison unit, and when it can be selected, it is displayed on the casting condition display unit so that it can be compared with the display after the input of the uninput set value. The casting condition determination method according to any one of claims 1 to 3 may be used.

  A condition that consists of multiple setting items that affect each other, such as casting conditions, is a combination of the setting values of each setting item, so if the number of input setting items increases, it corresponds to the remaining non-input setting values. In some cases, it is possible to specify an appropriate value or an inappropriate value of an item to be performed. Each time one input set value is input, it is determined whether or not the appropriate value or inappropriate value of the setting item corresponding to the remaining non-input set value can be selected from the database. Is displayed, it is easy for a worker with a low skill level to determine and input a non-input set value.

Next, as shown in claim 5, the setting item obtained by dividing one setting item composed of the appropriate value or the inappropriate value defined in the numerical value range into a plurality of values by dividing the numerical value range is the database. Including
Each time one input set value is input, the input set value that has been input and the already-set input set value are compared with the database as one casting condition by the casting condition comparison unit. ,
A warning is issued with respect to the input set value and the input set value that do not conform to the good casting condition, or to the input set value and the input set value that conform to the defective casting condition. The casting condition determination method according to claims 3 to 4 may be used.

  Since the casting condition is a combination of setting values of a plurality of setting items that affect each other, if the numerical value range of the setting item having a numerical value range is limited to one, the numerical value range depends on the size of the numerical value range. The numerical range of other affected items may be excessive, including an inappropriate numerical range, or conversely, the numerical range may be extremely narrow or completely lost. Therefore, in consideration of the characteristics of such casting conditions, in order to construct an appropriate database, one setting item consisting of an appropriate value or an inappropriate value defined in the numerical range is divided into a plurality of values by dividing the numerical range. The database may be configured to include the divided setting items.

  Thereby, even in the same setting item, the numerical value range of the appropriate value or the inappropriate value of another corresponding setting item is changed with respect to different input setting values within the numerical value range. That is, on the premise of dividing the numerical range, the total numerical value range including the appropriate numerical value or the appropriate numerical value value divided into one setting item is made wider than before the division, and the casting condition is selected. The numerical value range obtained by dividing the appropriate value or inappropriate value of the setting item can be made narrower than before the division. This is nothing less than the numerical range of the setting items consisting of appropriate values or inappropriate values defined in the numerical ranges of the non-defective casting conditions or the defective casting conditions being more appropriately narrowed down, and variations in casting conditions being increased. In addition, every time one input set value is input, a combination of the input set value and the input set value is compared with the database by the casting condition comparison unit as one casting condition. In addition, the numerical value range of the appropriate value or the inappropriate value of the input setting value is reviewed each time. As a result, even if it is an already entered set value that is determined to be an appropriate value at the time of input, a warning is issued if it is determined to be an inappropriate value as the number of input setting items increases, so the skill level is low Even an operator can set more appropriate casting conditions.

  Next, as shown in claim 6, each time one input set value is input, the appropriate value or the inappropriate value of the item corresponding to the input set value is determined by the casting condition comparison unit. 6. The casting condition determining method according to claim 5, wherein the casting condition determining method is preferably selected from the database and displayed on the casting condition display unit so as to be comparable with the display of the input set value.

  That is, each time one input set value is input, not only the input set value but also the already entered set value is reviewed each time the numerical value range of the corresponding setting item for the appropriate value or the inappropriate value, Since it is displayed so that it can be compared, it is clear where the input setting value is in the appropriate value or the numerical value range of the corresponding setting item, and the input setting value is determined to be an inappropriate value. If it is, the appropriate input set value can be re-input while being compared with the appropriate value or the inappropriate value corresponding to the displayed input set value. In addition, when the display of the appropriate value or incorrect value of the input setting value has been changed, other setting items for each setting item such as how much the setting item for the input setting value to be input changes other setting items. It is easy to understand the degree of the influence on the worker with low skill level, and helps to set more appropriate casting conditions.

Further, the object of the present invention is to set the casting conditions of the die casting machine as shown in claim 7.
A casting condition storage unit that stores in advance a good product casting condition or a defective product casting condition obtained from a molten metal behavior analysis result in a plunger sleeve from hot water supply to injection of a die casting machine using CAE, as a database;
A casting condition input section for inputting casting conditions;
A casting condition display section for displaying the input casting conditions;
The casting condition comparison unit that compares the input casting conditions with the database of the non-defective casting conditions or the defective casting conditions stored in the casting condition storage unit;
This is achieved by a casting condition judging device characterized by comprising:

  With such a casting condition determining apparatus, the casting condition determining method according to claim 1 is possible.

The casting condition determination method according to the present invention is set in the casting conditions of the die casting machine.
Using the CAE, the good product casting condition or the defective product casting condition obtained from the molten metal behavior analysis result in the plunger sleeve from hot water supply to injection is stored in advance as a database in the casting condition storage unit,
Set values of a plurality of setting items constituting the casting conditions of the die casting machine are input from the casting condition input unit, displayed as input setting values on the casting condition display unit,
The input set value is compared with the database stored in the casting condition storage unit by the casting condition comparison unit,
Since the warning is issued for the input set value that does not conform to the non-defective casting condition or the input set value that conforms to the defective casting condition, the load of analysis performed for each product or die is reduced, Even an operator with a low level of skill can set casting conditions for obtaining a good product in a short time.

In addition, the casting condition determination apparatus according to the present invention is set in the casting conditions of the die casting machine.
A casting condition storage unit that stores in advance a good product casting condition or a defective product casting condition obtained from a molten metal behavior analysis result in a plunger sleeve from hot water supply to injection of a die casting machine using CAE, as a database;
A casting condition input section for inputting casting conditions;
A casting condition display section for displaying the input casting conditions;
The casting condition comparison unit that compares the input casting conditions with the database of the non-defective casting conditions or the defective casting conditions stored in the casting condition storage unit;
The casting condition judging device is characterized by having a casting condition that reduces the load of analysis performed for each product or die, and can obtain a good product even for an operator with a low level of skill. Can be set in a short time.

It is a block diagram which concerns on the casting condition determination apparatus of Example 1 of this invention. It is a flowchart figure which concerns on the molten metal behavior analysis method in the plunger sleeve from the hot water supply to injection in the casting condition determination method of Example 1 of this invention. FIG. 3 is a conceptual diagram related to a phenomenon that a molten metal rides on a diverter end in the flowchart of FIG. 2. FIG. 3 is a conceptual diagram related to a phenomenon in which a molten metal temperature at a boundary surface between a plunger sleeve inner wall and a molten metal reaches a solidified layer forming temperature in the flowchart of FIG. 2. FIG. 4 is a conceptual diagram related to a phenomenon of air entrainment in a molten metal in the flowchart of FIG. 3. FIG. 4 is a conceptual diagram related to an oxide film formation phenomenon on an air contact portion surface of a molten metal in the flowchart of FIG. It is a flowchart figure which concerns on the casting condition determination method of Example 1 of this invention. It is a flowchart figure which concerns on the casting condition determination method of Example 2 of this invention.

  Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the accompanying drawings.

  A first embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a block diagram according to the casting condition determining apparatus of Embodiment 1 of the present invention. FIG. 2 is a flowchart relating to the molten metal behavior analysis method in the plunger sleeve from hot water supply to injection in the casting condition determination method according to the first embodiment of the present invention. FIG. 3 is a conceptual diagram related to the phenomenon of the molten metal climbing to the end of the flow divider in the flowchart of FIG. FIG. 3A shows a state in which the molten metal 41 supplied into the plunger sleeve 32 undulates as the plunger tip 31 moves forward, and the tip 41a rides on the diverter (biscuit portion) end 41b. FIG. FIG. 3C shows a state in which the tip 41 a riding on the diverter end 41 b is solidified as it is due to the return of the wave of the molten metal 41 in the plunger sleeve 32, and FIG. 3C shows the solidified tip 41 a as the plunger tip 31 advances. Shows the state of being mixed in the product part. FIG. 4 is a conceptual diagram relating to a phenomenon in which the molten metal temperature at the boundary surface between the inner surface of the plunger sleeve and the molten metal reaches the solidified layer forming temperature in the flowchart of FIG. 4A shows a state in which the molten metal 41 supplied into the plunger sleeve 32 generates a solidified layer 41e on the inner wall boundary surface of the plunger sleeve 32, and FIG. 4B shows an XX in FIG. 4A. It is sectional drawing in an arrow view. FIG. 5 is a conceptual diagram relating to the phenomenon of air entrainment in the molten metal in the flowchart of FIG. FIG. 5A shows a state in which the molten metal 41 supplied into the plunger sleeve 32 undulates as the plunger tip 31 advances, and FIG. 5B shows the plunger sleeve in the undulated state of the molten metal 41 in the plunger sleeve 32. FIG. 5C shows a state in which the air 41f entrained in the molten metal 41 is mixed into the product portion as the plunger tip 31 moves forward. . FIG. 6 is a conceptual diagram related to the oxide film formation phenomenon on the air contact surface of the molten metal in the flowchart of FIG. 6A shows a state where an oxide film 41g is generated on the air contact surface of the molten metal 41 supplied into the plunger sleeve 32, and FIG. 6B shows a cross-sectional view taken along the line XX in FIG. 6A. It is. FIG. 7 is a flowchart according to the casting condition determination method of Embodiment 1 of the present invention.

  First, the configuration of the casting condition determination device will be described. The range surrounded by the one-dot chain line in the block diagram shown in FIG. The casting condition determination device 5 includes four elements: a casting condition input unit 11, a casting condition comparison unit 23, a casting condition storage unit 19, and a casting condition display unit 13. The casting condition determination device 5 is connected to the die casting machine control unit 3 that controls the die casting machine 1 via the casting condition comparison unit 23. The die casting machine control unit 3 controls the die casting machine 1 based on the casting conditions transmitted from the casting condition comparison unit 23.

  The casting condition input unit 11 also serves as an operation unit of the casting condition determination device 5, not only for inputting and correcting casting conditions, but also for calling registered casting conditions and inputting / correcting a database of good casting conditions and defective casting conditions. The casting condition display unit 13 can also be set for display. Specifically, it is composed of manual input means such as a keyboard and a touch panel and electrical input / output means such as an input / output port enabling direct data input / output from a personal computer or the like. For relatively large volume data such as a database of good casting conditions and defective casting conditions, data created on a personal computer or the like is directly input from an electrical input / output means such as an input / output port. From manual input means such as. It is preferable that the database and registered casting conditions are periodically downloaded by a personal computer or the like and managed as the latest backup data. Moreover, when the manual input means provided also with display functions, such as a touch panel, is selected, you may share the function of the casting condition display part 13 mentioned later.

  The casting condition comparison unit 23 transmits the input set value from the casting condition input unit 11 to the casting condition storage unit 19 and compares the input set value with the appropriate value or the inappropriate value of the corresponding setting item in the database. . Further, the comparison result is transmitted to the casting condition display unit 13 and the registered casting condition is called up. Furthermore, it is possible to determine whether or not the appropriate value or inappropriate value of the setting item corresponding to the uninput setting value can be selected, or to compare the input setting value with the appropriate value or inappropriate value of the corresponding setting item. . Specifically, it is constituted by an electrical calculation means such as a processing unit.

  The casting condition storage unit 19 stores a database of non-defective casting conditions or defective casting conditions, registered casting conditions for each product or die, casting conditions being set, and the like. A value or improper value is provided, and a registered casting condition corresponding to a call of the registered casting condition is also provided. An appropriate value or an inappropriate value corresponding to an uninput set value or an input set value may be provided. Specifically, it is composed of electrical storage means such as a hard disk, various memory cards, and corresponding card slots.

  The casting condition display unit 13 displays input setting values of various casting conditions for each set item based on an instruction from the casting condition comparison unit 23. Further, a corresponding appropriate value or inappropriate value may be displayed from the database of good product casting conditions or defective product casting conditions so as to be comparable with the display of the input set value. Further, an appropriate value or an inappropriate value corresponding to an uninput set value or an input set value may be displayed. Specifically, it is constituted by a numerical counter such as a mechanical counter (numerical display), a liquid crystal panel type or LED panel type electric counter, or a liquid crystal panel. In view of worker visibility, a liquid crystal panel having a high degree of freedom in display design is preferable. Based on the instructions from the casting condition comparison unit 23, incorporate moving image elements such as blinking the display of the corresponding set value or changing the display color so that the improper input set value or input set value becomes clear. If there is a warning display or a message display indicating the content of the warning, the operator can be alerted more. Further, as described above, when the casting condition input unit 11 is a manual input means having a display function such as a touch panel, the function of the casting condition display unit 13 may be shared by the casting condition input unit 11.

  Next, the molten metal behavior analysis in the plunger sleeve from hot water supply to injection using CAE will be described. This analysis is performed in order to obtain a casting condition that can avoid the occurrence of a defective product factor in the plunger sleeve from hot water supply to injection, which is difficult to calculate with a calculation formula. Analyzing various patterns in advance by appropriately changing each set value of a plurality of setting items constituting the casting conditions, and evaluating the obtained analysis results based on determination criteria described later, these analysis results Can be reflected in good product casting conditions or defective product casting conditions. And this good product casting condition or defective product casting condition is stored in advance in the casting condition storage unit 19 of the casting condition judging device 5 as a database of combinations of setting values of the respective setting items. The database is positioned as a criterion for determining whether the input setting value to be input or the input setting value that has been input is an appropriate value.

  The software used for this analysis may be appropriately selected from various commercially available molten metal behavior analysis software for casting molds having a melt behavior analysis function in the plunger sleeve. An example is “ADSTEFAN (registered trademark)” (Adstefan) manufactured by Ibaraki Hitachi Information Service Co., Ltd. The computer used for the analysis is preferably high-performance, but any computer satisfying the specification specified by the analysis software used may be used, and a commercially available personal computer can be used. Moreover, since analysis software marketed is used, the analysis method itself does not include special contents. Therefore, the outline of this analysis will be described using the flowchart of FIG. 2 and conceptual diagrams showing various phenomena of FIGS. 3 to 6 according to FIG.

  First, as shown in FIG. 2, an analysis model is constructed. The object of analysis is the behavior of the molten metal in the plunger sleeve from hot water supply to injection in the horizontal die casting machine. The analysis range is from the start of hot water supply to the plunger sleeve by the hot water supply device to the completion of injection filling (from injection speed control to injection pressure control). Until switching). Therefore, the analysis model to be constructed is for the plunger sleeve / plunger tip and the diverter (biscuit) part. Since the gate inlet and the inside of the mold continuous to the flow divider are not the object of this analysis, they are not necessary for the construction of the analysis model.

  First, drawing data (cad data) of these target parts is necessary for constructing this analysis model. For the plunger sleeve / plunger tip, the standard specifications are usually decided by the die casting machine manufacturer as the size and shape variations for one die casting machine as an accessory of the die casting machine, and the customer specifies a special size and shape. Unless there is, there is a die-casting machine manufacturer that arranges or manufactures what the customer chooses from these variations and delivers it to the customer as an accessory of the die-casting machine. Therefore, it is easy for a die casting machine manufacturer to obtain these drawing data. Next, the shunt part is a part on the mold side, and it is necessary to obtain drawing data from the mold manufacturer. However, the inner diameter of the diverter portion is the same as the inner diameter of the plunger sleeve, and the standard thickness of the diverter portion is determined from the inner diameter of the plunger sleeve and the device size of the die casting machine. In addition, in the analysis of the phenomenon of the molten metal climbing onto the end of the diverter, which will be described later, information on the height of the end of the diverter is sufficient, and this height is merely a setting item for analysis. Therefore, if it is a die-casting machine manufacturer, it is easy to construct an analysis model for the plunger sleeve / plunger tip and the diverter part.

  Next, input analysis conditions. The input items required for the constructed analysis model are: hot water supply (casting weight), hot water supply speed (laddle tilt speed), injection delay time (time from completion of hot water supply to injection start), injection low speed, injection high speed , Injection speed switching position, molten metal temperature in the melting and holding furnace, etc., including all setting items of basic casting conditions. When inputting these analysis conditions, it is first determined whether or not the sleeve filling rate is appropriate. The sleeve filling rate is the ratio of the volume of the molten metal supplied to the inner volume of the plunger sleeve, and although it depends on other analysis conditions, an appropriate value is usually determined from the range of 30 to 60%. If the set values of the injection low speed, injection high speed, and injection speed switching position are not appropriate for the sleeve filling rate, air is entrained in the molten metal in the plunger sleeve, or if the sleeve filling rate is too low, Since the molten metal is cooled rapidly, a solidified layer or an oxide film is formed, which in any case becomes a cause of product defects. Therefore, in order to avoid useless analysis, the analysis is executed when the sleeve filling rate is appropriate after the input analysis conditions are determined by the analysis software to determine whether the sleeve filling rate is appropriate. Since the criteria for determining whether or not the sleeve filling rate is appropriate can be set in the analysis software, the analyst may set the criteria appropriate for the plunger sleeve to be analyzed and the die casting machine to which the sleeve is attached. Therefore, it is easy for the die casting machine manufacturer to input these analysis conditions.

  Next, the analysis result is output. The analysis result can be selected from various output forms by various analysis software. Among these, the output form in 3D animation that allows easy evaluation of analysis results is preferable.

Next, the analysis result is evaluated. What is evaluated is whether air is entrained in the solidified pieces, the oxide film, and the molten metal, which can be mixed into the product and cause defects. In the present invention, the determination criteria are made by paying attention to the following five phenomena related to these failure factors. The phenomena are listed below.
Occurs in the plunger sleeve,
1) The phenomenon of the molten metal climbing to the end of the diverter 2) The phenomenon of the molten metal temperature decreasing to the solidified layer formation temperature at the boundary surface between the plunger sleeve inner wall and the molten metal 3) The phenomenon of the molten metal temperature decreasing to the predetermined temperature 4) The air to the molten metal 5) There are five phenomena of oxide film formation on the air contact surface of the molten metal. In the following, the above five phenomena and each criterion will be described.

  The phenomenon 1) will be described with reference to FIG. FIG. 3 is a conceptual diagram related to the phenomenon of the molten metal climbing to the end of the flow divider in the flowchart of FIG. 2. As shown in FIG. 3A, the molten metal 41 supplied by a hot water supply device (not shown) from the hot water supply hole 32 a (opening) of the plunger sleeve 32 undulates in the plunger sleeve 32. After the hot water supply is completed and the injection delay time elapses, the plunger tip 31 starts to advance in the direction indicated by the arrow 31c. However, when the injection low speed forward speed is too high with respect to the sleeve filling rate, the ripple of the molten metal 41 is amplified (41c The tip portion 41a rides on the diverter (biscuit portion) end 41b. Here, reference numeral 33 is a fixed platen, 34 is a fixed mold, 36 is a movable mold, and 35 is a dividing surface (parting line) between the fixed mold 34 and the movable mold 36.

  Next, as shown in FIG. 3 (b), only the tip 41a riding on the diverter end 41b is left and solidifies as it is due to the return (41d) of the undulation of the molten metal 41. Then, as shown in FIG. 3C, the solidified tip portion 41 a is mixed into the product portion as the plunger tip 31 advances. When the tip 41a is mixed into the product as a solidified piece in this way, the tip 41a and its surroundings are not completely integrated. Therefore, if the mixing position is on the product surface, the appearance of the product is deteriorated and the strength is reduced. If the mixing position is inside the product, it will cause a decrease in strength, and a product that requires strength will become a serious defect. Therefore, it is determined that a defective product is generated when the phenomenon 1) occurs.

  Here, it is needless to say that the phenomenon 1) is a criterion applied only to the horizontal die casting machine and is not applied to the analysis of the molten metal behavior in the plunger sleeve from the hot water supply to the injection of the vertical die casting machine.

  The phenomenon 2) will be described with reference to FIG. FIG. 4 is a conceptual diagram relating to a phenomenon in which the molten metal temperature at the boundary surface between the inner surface of the plunger sleeve and the molten metal reaches the solidified layer forming temperature in the flowchart of FIG. Due to factors such as when the plunger sleeve 32 is not sufficiently preheated at the start of operation, the temperature in the vicinity of the boundary surface between the molten metal 41 and the plunger sleeve 32 drops rapidly to the solidified layer formation temperature. Then, as shown in FIGS. 4A and 4B, a solidified layer 41 e is generated at the inner wall boundary surface of the plunger sleeve 32. The generated solidified layer 41e becomes a solidified piece as the plunger tip 31 advances, and enters the product. The problems caused by the mixing of the coagulated pieces into the product are as described above. Therefore, it is determined that a defective product is generated when the phenomenon 2) occurs.

  The phenomenon 3) will be described. Although there is no figure relating to the phenomenon of 3) above, the same element numbers as in the other figures are quoted as they are. If the temperature of the molten metal 41 is lower than the reference value for some reason and falls to a predetermined temperature at the time when the plunger sleeve 32 is heated, even if the plunger sleeve 32 is sufficiently preheated, the flow of the molten metal 41 It is predicted that the mold will not be filled up to the end of the mold due to the decrease in properties. If the end of the mold is not fully filled, the shape and appearance of the molded product will be deteriorated, as well as the strength of the end of the product due to the solidification of the part in the middle of filling and insufficient injection filling pressure to the end It causes a decline and becomes a serious defect. Therefore, it is determined that a defective product is generated when the phenomenon 3) occurs.

  The phenomenon 4) will be described with reference to FIG. FIG. 5 is a conceptual diagram related to the phenomenon of air entrainment in the molten metal in the flowchart of FIG. As shown in FIG. 5A, the molten metal 41 supplied by a hot water supply device (not shown) from the hot water supply hole 32a (opening portion) of the plunger sleeve 32 undulates in the plunger sleeve 32 (41c). After the hot water supply is completed and the injection delay time has elapsed, the plunger tip 31 starts to advance in the direction indicated by the arrow 31c. However, when the injection low speed forward speed is too high with respect to the sleeve filling rate, as shown in FIG. In addition, the air 41 f in the plunger sleeve 31 is caught in the molten metal 41 by the undulation of the molten metal 41. And as shown in FIG.5 (c), with the advance of the plunger chip | tip 31, the air 41f caught in the molten metal 41 mixes in a product part. If the air 41f is mixed into the product in this way, as in the case where the solidified pieces are mixed, if the mixing position is on the product surface, the appearance of the product is deteriorated and the strength is reduced. If the mixing position is inside the product, it will cause a decrease in strength, and a product that requires strength will become a serious defect. Therefore, it is determined that a defective product is generated when the phenomenon 4) occurs.

  The phenomenon 5) will be described with reference to FIG. FIG. 6 is a conceptual diagram related to the oxide film formation phenomenon on the air contact portion surface of the molten metal in the flowchart of FIG. When the molten metal 41 supplied to the plunger sleeve 32 is exposed to air for a time exceeding the reference value because the hot water supply speed is slow or the injection delay time is too long, FIG. 6 (a) and FIG. 6 (b) ), An oxide film 41g is generated on the air contact surface of the molten metal 41. The generated oxide film 41g is mixed into the product as the plunger tip 31 advances. The problem caused by the mixing of the oxide film into the product is the same as the problem caused by the mixing of the solidified piece into the product. Therefore, it is determined that a defective product is generated when the phenomenon 5) occurs.

  According to the applicant's experience of molten metal behavior analysis and actual casting, it can be considered that the failure factors of most products generated in the plunger sleeve at the time of injection are due to the occurrence of the above five phenomena. Therefore, if at least one of these five phenomena occurs, it is determined that a defective product has occurred, and the numerical value of each setting item of the analysis conditions at that time is reflected in the defective product casting condition. To the good casting conditions. In this way, various analysis conditions such as plunger sleeve, hot water supply amount, injection-related, etc. are appropriately changed and repeated analysis is performed, and these analysis results are reflected in a database of good product casting conditions or defective product casting conditions to obtain a calculation formula. Therefore, it is possible to construct a database of casting conditions that is difficult to calculate from the above and can prevent the occurrence of product defect factors in the plunger sleeve during injection.

  Here, the reason why the molten metal behavior analysis result in the plunger sleeve is reflected in the non-defective casting condition or the defective casting condition, not the molten metal behavior analysis result or the product solidification analysis result in the mold will be described.

  The causes of product defects in casting using a die casting machine are roughly divided into those that occur in the plunger sleeve during injection and those that occur in the mold. As described above, it is difficult to calculate the cause of defects of these products by the calculation formula and can be predicted only from the analysis performed for each product or die. However, the first reason is not to analyze the molten metal behavior in the mold or analyze the solidification of the product, but also to cause defective products in the plunger sleeve from hot water supply to injection, such as solidified pieces, oxide film and air. If entrainment or the like occurs, the solidified pieces, oxide film, and air are mixed into the product, so that defective products are almost certainly generated. Next, the shape in the mold has various types of products and is complicated, whereas the shape in the plunger sleeve has few types and is simple. This makes it easy to construct the target analysis model, and the time required for the analysis based on one analysis condition can be reduced because of the simplicity of the analysis model. In addition, the number of plunger sleeves adopted as standard in one type of horizontal die casting machine is usually about two to three, which is overwhelmingly less than the types of products or molds cast by the horizontal die casting machine. Therefore, the time required to analyze the molten metal behavior by combining various analysis conditions for each type of plunger sleeve can be shortened, and the data volume of the analysis result reflected in the non-defective casting condition or the defective casting condition is reduced. As a result, the database for good casting conditions or defective casting conditions reflecting the analysis result also has a small data capacity, so that it can be stored in advance in the casting condition storage unit as a highly versatile database.

  On the other hand, the cause of product defects occurring in the mold can only be predicted from the molten metal behavior analysis results and the product solidification analysis results in the mold. Therefore, it is necessary to analyze the molten metal behavior and the solidification analysis of the product, and find the casting conditions for obtaining a good product from the analysis result. However, unlike the plunger sleeve, this analysis is performed in advance for all products or molds that may be cast in the future, and the analysis results are reflected in the non-defective casting conditions or defective casting conditions. It is practically difficult to create.

  Also, failure factors that occur in the mold should be avoided in the mold side design and setting items such as overflow, runner, heating / cooling medium flow path shape and arrangement, heating / cooling control in the mold. Is preferred. This is because if it is attempted to prevent the cause of product defects that occur in the mold by setting items that can be controlled on the horizontal die casting machine side, the casting conditions set on the die casting machine side will become unreasonable, and appropriate casting will occur. This is because setting items that deviate from the conditions may occur.

  In this way, the molten metal behavior analysis results in the plunger sleeve from hot water supply to injection can avoid the occurrence of various defective factors in the plunger sleeve, which are difficult to calculate from the calculation formula, and the molten metal behavior in the mold Unlike analysis results, it is highly versatile, so a database of good casting conditions or defective casting conditions that reflect these analysis results is sufficiently meaningful to be positioned as a criterion for more appropriate casting conditions for obtaining good products. . Moreover, since the casting conditions set based on this database can avoid most of the defective factors of the product generated in the plunger sleeve, if the product cast by the casting conditions is defective, the defective It is clear that it is very likely that the factor occurred on the mold side. Therefore, in this case, the operator can concentrate on the examination of the setting items on the mold side, and the time required for setting the casting conditions for obtaining good products can be shortened.

  Next, the casting condition determination method will be described with reference to FIGS. FIG. 1 is a block diagram according to the casting condition determining apparatus of Embodiment 1 of the present invention. FIG. 7 is a flowchart according to the casting condition determination method of Embodiment 1 of the present invention.

  First, a database of good casting conditions or defective casting conditions stored in advance in the casting condition storage unit 19 will be described. The casting conditions in this database are set within a certain numerical range for each set value that can be selected for each set value that can be selected for the set items that can be selected in the molten metal behavior analysis in the plunger sleeve from hot water supply to injection. Setting items for which setting values are arbitrarily selected are analyzed based on the casting conditions combined for each numerical range that can allow for variation in one setting item, and the analysis results are evaluated based on the aforementioned criteria. Casting conditions. Further, the casting condition may be a casting condition including both a good casting condition based on the analysis result and a defective casting condition based on the analysis result. Specifically, the appropriate amount of hot water specified in one numerical range based on the amount of hot water that the sleeve filling rate obtained from the amount of hot water supplied to the plunger sleeve internal volume satisfies the appropriate value (range) or inappropriate value (range) On the other hand, other setting items such as injection low speed, injection high speed, injection speed switching position, pressurization time, casting pressure, mold clamping force, appropriate values (ranges) of each setting item, This is a casting condition in which an appropriate value (range) is combined.

  As shown in FIG. 7, first, it is selected whether or not it is a registered casting condition. In the case of a new product or a new mold, a new product / mold number is input from the casting condition input unit 11. The product / die number input from the casting condition input unit 11 is compared with the product / die number of the registered casting condition in the casting condition storage unit 19 to determine whether the input is a new casting condition or the registered casting condition. Flow may be used.

  Next, casting conditions are set for each setting item. The setting items are displayed in the casting condition input unit 11, and the input order is not limited. For example, it is assumed that the plunger sleeve inner diameter (plunger tip outer diameter), the plunger sleeve length, and the hot water supply amount are input. Each time each setting item is input, the casting condition comparison unit 23 compares the input setting value with the corresponding appropriate value or inappropriate value in the database of the casting condition storage unit 19 to determine whether the input setting value is an appropriate value or an inappropriate value. As described above, since the standard specification is determined for the plunger sleeve inner diameter and length, these specifications (dimensions: for example, inner diameter φ90 mm and φ100 mm, length 400 mm are set as appropriate values for the setting items that can be selected. Etc.) are stored in the database. Therefore, if an operator mistakenly inputs a different plunger sleeve inner diameter or length of another die casting machine, the casting condition comparison unit 23 determines that the value is inappropriate, and the setting value input to the casting condition display unit 13 is inappropriate. At the same time as a value, a warning is issued by flashing the display of the corresponding input set value on the casting condition display unit 13 or displaying a warning message, etc., to alert the worker to the worker. A voice generation unit may be provided, or a voice generation unit of a die casting machine may be used, so that warnings or warnings using voice messages may be used together to more effectively alert the operator. In addition, for setting items for which set values that can be selected are determined as described above, when an appropriate value or inappropriate value corresponding to the input set value is displayed in a manner comparable to the display of the input set value, It is possible to prevent an input error.

  The plunger sleeve inner volume is specified by the input set values of the plunger sleeve inner diameter and length. When the hot water supply amount is input to this, the sleeve filling rate is specified. When the sleeve filling rate is input, the hot water supply amount is specified. (Strictly speaking, other setting items may be necessary, but this is assumed for the sake of simplicity.) That is, for the setting items of the plunger sleeve inner diameter and length, The appropriate value or inappropriate value of the hot water supply amount is determined from the appropriate value or inappropriate value of the sleeve filling rate corresponding to the plunger sleeve inner diameter and length, and the appropriate value of the sleeve filling rate depends on the plunger sleeve inner diameter and length. There is a mutual relationship that it is determined from an appropriate value or an inappropriate value of the corresponding hot water supply amount. Since both the hot water supply amount and the sleeve filling rate are set items in which a set value is arbitrarily selected within a certain numerical range, when any one of the input set values is input, the casting condition comparison unit 23 specifies from the mutual relationship. Is compared with the appropriate value or inappropriate value determined from the other appropriate value or inappropriate value on the database, and if one input set value is not within the corresponding appropriate value range (or becomes an inappropriate value) If so, a warning is issued as described above. In this case, it is necessary to correct one of the input set values, but the reference value and allowable range of the appropriate value or the inappropriate value corresponding to the input set value and the upper limit value or the corresponding value can be compared with each input set value. When the lower limit value is displayed, it is possible to prevent an erroneous input by the operator exceeding the allowable range.

  In this way, if the input set value is an inappropriate value, the input set value is displayed on the casting condition display unit 13 as an inappropriate value, a warning is issued, and the corresponding appropriate value can be compared with the input set value. Or, an inappropriate value is displayed and the operator is prompted to input again. If the input set value is an appropriate value, the input set value is displayed as an appropriate value on the casting condition display unit 13, and the casting under setting which is temporarily stored in the casting condition storage unit 23 by the casting condition comparison unit 23. The conditions and the corresponding casting conditions in the database are compared. If an appropriate value or an inappropriate value of the setting item corresponding to the uninput set value can be selected, it is displayed on the casting condition display unit 13 to guide the operator to input the uninput set value. In addition, every time the input set value is input, the casting condition under setting temporarily stored in the casting condition storage unit 19 by the casting condition comparison unit 23 is compared with the corresponding casting condition in the database, and the setting is completed. Will be confirmed. After the setting is completed, the operator confirms whether or not the setting needs to be corrected. If the setting is to be corrected, the above flow is repeated. If the setting is not to be corrected, the casting set by the first entered product / die number is performed. The conditions are stored (registered) in the casting condition storage unit 19, and at the same time, new casting conditions are transmitted to the die casting machine control unit 3. Thereafter, operations and control are performed by the die casting machine 1 and the die casting machine control unit 3.

  In this manner, each time an input set value is input, it is compared with an appropriate value or an inappropriate value in the database corresponding to the input set value, and as a result, a warning is issued for an incorrect input set value. Therefore, it is possible to set the casting conditions for obtaining a good product in a short time even for a worker with low skill level or a product or a mold to be cast for the first time.

  Once the casting conditions are stored (registered), they can be called by product / die number, and the casting conditions can be easily reset. In addition, even if the same product has multiple dies depending on whether there are improvements, etc., each with different casting conditions, even if the casting conditions are different, one die, or the casting conditions differ according to the season. By managing with numbers, it is possible to manage the casting conditions in detail.

  Further, according to the flow of FIG. 7, the input set value of the setting item that has received the warning is always corrected and input. In order for an operator with a low skill level to set casting conditions, such a flow is preferable in order to prevent an inappropriate input set value from being input. However, if a highly skilled worker pursues the best casting conditions according to the customer's intention, or in the R & D department, the researcher determines the product status based on the casting conditions including extreme input settings. In view of the case of investigation, a special setting mode (for example, a trial mode, a development mode, etc.) that allows an inappropriate value to be input may be selectable at the time of casting condition setting or every time a warning occurs. Furthermore, it is preferable that the special good product casting conditions obtained in this special setting mode can be additionally input from the casting condition input unit 11 to the database of the casting condition storage unit 19 as appropriate. However, even in this special setting mode, it is needless to say that a warning for an input of an inappropriate value and a safety device that makes it difficult to set an input set value that exceeds the specifications of safety and die casting machine are necessary.

  A second embodiment of the present invention will be described with reference to FIGS. FIG. 1 is a block diagram according to the casting condition determining apparatus of Embodiment 1 of the present invention. FIG. 8 is a flowchart according to the casting condition determination method of Embodiment 2 of the present invention. Also in Example 2, the configuration of the casting condition determination apparatus is the same as the apparatus configuration of the block diagram shown in FIG. The difference between the second embodiment and the first embodiment is that the database configuration of the non-defective casting condition or defective casting condition stored in the casting condition storage unit 19 in the casting condition determination method and the configuration of this database are used. By comparing not only the input setting value but also the input setting value including the input setting value with the casting condition in the database as the casting condition under setting, the corresponding appropriate value or improper value of the input setting value can be obtained. These are the two points that narrow down the numerical range. Since the other points are the same as the casting condition determination method of Example 1, only the differences will be described.

  FIG. 8 is a flowchart according to the casting condition determination method of Embodiment 2 of the present invention. First, a description will be given of the difference in the structure of the database of good product casting conditions or defective product casting conditions stored in the casting condition storage unit 19, which is not shown in FIG. As described above, since the casting condition is a combination of setting values of a plurality of setting items that affect each other, if the numerical value range of the setting item having a numerical value range or an inappropriate value is limited to one, Depending on the size of the numerical range, the numerical range of other affected items may become excessive, including an inappropriate numerical range, or conversely, the numerical range may become extremely narrow or disappear altogether. In Example 1, since the numerical value range of the appropriate value or inappropriate value of the database of good product casting conditions or defective product casting conditions is assumed to be one numerical value range that can allow variation of one setting item, The casting conditions are configured such that an appropriate value range of related items exists within a predetermined width so as not to include an inappropriate range. Therefore, one configured good product casting condition tends to be so-called champion data in which the numerical range of each setting item is limited to a relatively narrow range.

  Of course, even if it is the database of the casting conditions comprised by the champion data, it is possible to set the casting conditions in which a non-skilled worker can obtain a good product in a short time. However, when trying to correct the input setting value of a certain setting item in order to further improve the quality of the product, the correction range exceeds the corresponding numerical range of the appropriate value (or the numerical value range of the inappropriate value) There is a case where it cannot be corrected. That is, even if the input setting value of the A setting item is a numerical value slightly exceeding the upper limit of the numerical range of the corresponding appropriate value, the input setting value of the B and C setting items is changed to the lower limit of the numerical range of the corresponding appropriate value. If the numerical value is slightly over, it can be cast, or it can be considered that a good product can be obtained under that condition. Even in such a case, it is possible to cope with it by correcting the casting conditions of the database. However, correcting the casting conditions of the database itself may reduce the reliability of the database. It is preferable that frequent correction of casting conditions in the database is avoided.

  Therefore, in Example 2, in order to construct a more appropriate database in consideration of the characteristics of such casting conditions, the database includes one setting item consisting of an appropriate value or an inappropriate value defined in a numerical range. The setting items are divided into a plurality of values by dividing the numerical range, and different numerical ranges are selected for other setting items for each of the divided setting items.

  For example, it is assumed that the upper limit and the lower limit of the numerical range of the appropriate value of the sleeve filling rate are expanded by a predetermined amount under one casting condition in the database, and the expanded numerical range is divided into four. As a result, each divided numerical range is narrower than the numerical range before the division. Considering other setting items of the same casting conditions with respect to the input set value on the upper limit side (higher sleeve filling rate / higher hot water supply amount than the reference value) of the four divided numerical range, the appropriate value of the injection low speed is The upper limit of the conventional appropriate value can be accelerated to a range exceeding the predetermined amount, or the appropriate value of the injection speed switching position can be separated from the mold to the range exceeding the predetermined upper limit of the conventional appropriate value. To do. Also, under different casting conditions in the database, the upper and lower limits of the appropriate value range of the injection delay time (time from the completion of hot water supply to the start of injection) included in various timer values are expanded by a predetermined amount, and the expanded numerical range Is divided into three. As described above, each divided numerical range is narrower than the numerical range before the division. Considering other setting items of the same casting conditions for the input set value that exceeds the conventional appropriate value by a predetermined amount on the upper limit side divided into three, the appropriate value of the injection low speed is the same as the conventional upper limit. It is possible to speed up to a range exceeding a predetermined amount. This is because the undulation of the molten metal generated by the hot water supply is rectified by increasing the time from when the molten metal is supplied to the plunger sleeve until the injection. A similar effect can be obtained even if the hot water supply speed is lowered.

  In this way, with regard to setting items consisting of appropriate values or inappropriate values defined in the numerical range, one setting item can be divided into a plurality of values by dividing the numerical range, so that one numerical value range can be divided. The total value range including the appropriate numerical value range or the appropriate numerical value range for the setting item is broader than before the division, and the appropriate value or inappropriate value value for the setting item selected as the casting condition is divided. It is possible to make the numerical range made narrower than before the division. This is nothing less than the numerical range of the setting items consisting of appropriate values or inappropriate values defined in the numerical ranges of the non-defective casting conditions or the defective casting conditions being more appropriately narrowed down, and variations in casting conditions being increased. Such a database of non-defective casting conditions or defective casting conditions is a premise for differences from the casting condition determination method described later in Example 1.

  Next, differences from the first embodiment of the casting condition determination method shown in FIG. 8 will be described. The range surrounded by the alternate long and short dash line in FIG. 8 is the difference from the casting condition determination method of the first embodiment. For the input of a certain input set value, whether the input set value is an appropriate value or not is compared with the appropriate value or the inappropriate value of the corresponding setting item in the casting condition storage unit 19 by the casting condition comparison unit 23 Similar to Example 1. If it is determined that the input set value is an appropriate value, then in Example 2, the input set value and the input set value temporarily stored in the casting condition storage unit 19 are currently being set. The casting conditions are compared with the individual casting conditions in the database of non-defective casting conditions or defective casting conditions that are also stored in the casting condition storage unit 19. As a result, if the casting conditions being set completely satisfy the non-defective casting conditions in the database, or if there are no defective casting conditions that satisfy all the set values, the input set value and the input set value have been entered. Are determined to be appropriate values, and the process proceeds to the next step. If either the input set value or the input set value does not satisfy the non-defective casting condition, or if the defective casting condition is satisfied, either the input set value determined to be inappropriate or the input set value In order for the operator to know the corresponding set value, a warning is issued on the casting condition display unit 13 by blinking of the display and the corresponding appropriate value or inappropriate value is displayed in a comparable manner at the same time. When a warning is issued, the operator inputs the casting condition according to the corresponding proper value or improper value displayed so as to be able to compare the input set value and the input set value of the setting item determined to be an inappropriate value. What is necessary is just to input again from the part 11. In this way, the operator narrows down the numerical range that can be compared with the warning issued from the casting condition determination device 5 as the number of setting items increases and can be compared with the corresponding input setting value. According to the appropriate value or the inappropriate value, not only the input set value but also the input set value, the numerical range can be narrowed down, and more appropriate casting conditions can be set.

  In the first embodiment, the step of determining by the casting condition comparison unit 23 whether or not the appropriate value or the inappropriate value of the setting item corresponding to the non-input set value can be selected from the database is also in the setting described above in the second embodiment. After the comparison between the casting conditions and the database, it is performed in the same manner, and if it can be selected, it is displayed on the casting condition display unit 13 to guide the operator to input the non-input set value. Since this step is performed each time an input set value is input, if the input set value that was an appropriate value at the time of input is determined to be an inappropriate value and the input set value is re-input, this input is not performed. If the appropriate value or inappropriate value of the setting item corresponding to the setting value needs to be changed, this display is also changed. Therefore, the operator can input an appropriate input setting value while comparing the non-input setting value with the appropriate value or the inappropriate value of the setting item corresponding to the narrowed non-input setting value. As in the first embodiment, a special setting mode that allows an inappropriate value to be input may be provided.

  As described above, appropriate casting conditions can be set by a casting condition determination method and determination apparatus according to the present invention even for an operator having a low skill level. Moreover, the casting conditions set by the casting condition determination method and the determination apparatus of the present invention are the casting conditions under which a good product can be obtained from the casting conditions calculated by the calculation formula. In addition, setting items that are estimated to be able to solve the cause of defects of various casting condition values, or to be able to obtain better products, by casting the product by actual casting and the experience and intuition of the operator. Even if it becomes necessary to repeat the work of re-input, every time an input set value is input, the appropriate value or incorrect value of the setting item corresponding to the input set value or the non-input set value is reviewed, Since it is redisplayed, the influence of each setting item on the other setting items, such as which setting item the changed setting item changes, is easy to understand even for low-skilled workers. Since it is useful for input, the repetitive work can be reduced. Furthermore, since it is very likely that the failure factor has occurred on the mold side, the operator can concentrate on the examination of the setting items on the mold side. As a result, even an operator with a low skill level can set casting conditions that can obtain a good product in a short time.

  The present invention can be implemented in various forms without being limited to the above-described embodiment without departing from the gist of the present invention. For example, the four elements provided in the casting condition determination device explain that the functions that can be shared with each other may be shared in the first embodiment. Moreover, you may make the function of the casting condition display part 13 of the casting condition determination apparatus 5 shown in FIG. Furthermore, the die casting machine control unit 3 may share the function itself of the casting condition determination device 5. In addition, in consideration of the configuration and functions of the casting condition determination device 5, all the functions of the casting condition determination device 5 can be executed by a desktop computer or a notebook computer, and are waterproofed beside the die casting machine to be controlled. You may install in the state provided with a dust cover. Alternatively, a computer capable of executing all the functions of the casting condition determination device 5 is prepared at the casting site which is collectively managed by communicating the control of a plurality of die casting machines with the main control device. The main controller may be connected. With such a configuration, the casting condition determination method of the present invention can be executed without modification even in an existing die casting machine. In addition, the above-described embodiment is related to the casting condition determination method in the horizontal die casting machine, but the vertical die casting machine is also determined to determine the occurrence of defective products that can be excluded due to its structure. Excluding the criterion “1) Phenomenon that the molten metal reaches the end of the diverter” is applicable in the same manner as in the horizontal die casting machine.

  The casting condition determination method and determination apparatus according to the present invention reduces the analysis load performed for each mold or product, and allows the casting conditions for obtaining a good product to be obtained even for an operator having a low skill level in a short time. Can be set. This effect is achieved by providing a determination device capable of performing such a casting condition determination method and a die casting machine having a casting condition determination function by a die casting machine maker such as the applicant, thereby improving a computer use environment. In casting sites where it is difficult to secure human resources with knowledge of both computer systems and casting technology, and in casting sites where it is difficult to secure the necessary number of workers who are skilled in casting due to the separation of personnel and the aging of workers. It can also be played, and the industrial utility value is extremely high for those involved in the foundry industry.

5 Casting condition determination device 11 Casting condition input unit 13 Casting condition display unit 19 Casting condition storage unit 23 Casting condition comparison unit

Claims (7)

In setting the casting conditions of the die casting machine,
Using the CAE, the good product casting condition or the defective product casting condition obtained from the molten metal behavior analysis result in the plunger sleeve from hot water supply to injection is stored in advance as a database in the casting condition storage unit,
Set values of a plurality of setting items constituting the casting conditions of the die casting machine are input from the casting condition input unit, displayed as input setting values on the casting condition display unit,
The input set value is compared with the database stored in the casting condition storage unit by the casting condition comparison unit,
A casting condition determination method, wherein a warning is issued for the input set value that does not conform to the good casting condition or the input set value that conforms to the defective casting condition. The database is
In the plunger sleeve confirmed from the molten metal behavior analysis result,
1) The phenomenon of the molten metal climbing to the end of the diverter 2) The phenomenon of the molten metal temperature decreasing to the solidified layer formation temperature at the boundary surface between the plunger sleeve inner wall and the molten metal 3) The phenomenon of the molten metal temperature decreasing to the predetermined temperature 4) The air to the molten metal 5) In the database of non-defective casting conditions or defective casting conditions determined from the judgment criteria for determining the occurrence of at least one of the oxide film forming phenomena on the air contact surface of the molten metal as the occurrence of defective products The casting condition determining method according to claim 1, wherein the casting condition is determined. Appropriate value or inappropriate value defined by either the numerical value range defined by the database as a reference value and an upper and lower allowable range relative to the reference value, or the numerical value range defined as an upper limit value and a lower limit value Including setting items consisting of
Each time one input set value is input, the appropriate value or the inappropriate value of the setting item corresponding to the input set value is selected from the database by the casting condition comparison unit, and the input set value and The casting condition determination method according to claim 1, wherein the casting condition is displayed on the casting condition display unit in a comparable manner.   Each time the one input set value is input, whether or not the appropriate value or the inappropriate value of the setting item corresponding to the non-input set value that has not yet been input can be selected from the database, the casting condition comparison unit 4. The casting condition according to claim 1, wherein the casting condition is displayed on the casting condition display unit so as to be comparable with a display after the input of the uninput set value when the selection is possible. Judgment method. The database includes setting items obtained by dividing one setting item consisting of the appropriate value or the inappropriate value defined in the numerical value range into a plurality of values by dividing the numerical value range,
Each time one input set value is input, the input set value that has been input and the already-set input set value are compared with the database as one casting condition by the casting condition comparison unit. ,
A warning is issued with respect to the input set value and the input set value that do not conform to the good casting condition, or to the input set value and the input set value that conform to the defective casting condition. The casting condition determination method according to claim 3.   Each time the one input setting value is input, the appropriate value or the inappropriate value of the item corresponding to the input setting value is selected from the database by the casting condition comparison unit, and the input setting value The casting condition determination method according to claim 5, wherein the casting condition is displayed on the casting condition display unit so as to be comparable with the display. In setting the casting conditions of the die casting machine,
A casting condition storage unit that stores in advance a good product casting condition or a defective product casting condition obtained from a molten metal behavior analysis result in a plunger sleeve from hot water supply to injection of a die casting machine using CAE, as a database;
A casting condition input section for inputting casting conditions;
A casting condition display section for displaying the input casting conditions;
The casting condition comparison unit that compares the input casting conditions with the database of the non-defective casting conditions or the defective casting conditions stored in the casting condition storage unit;
A casting condition determining apparatus comprising:

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