JPH02142638A - Process control system for casting product - Google Patents

Abstract

PURPOSE:To automate process control by planting projecting pieces, which plural pieces are one set, on a base plate of a pattern, attaching to the pattern body, reading the projecting pieces on surface of a casting product molded and cast and executing the control of the casting product. CONSTITUTION:There are plural fitting holes 6 on the base plate 2 in the pattern 1 for control. The rule for displaying the specific letters and numerals is preset and according to this rule, the planting pieces 3 are planted in the fitting holes 6 at the prescribed position. The pattern 1 for control completing assemble in attached to the practical pattern for casting product and at the time of molding and pouring, the projecting pieces 27 are cast on the casting product. This casting product is placed at a reader. The reader detects projecting lines 7, 8 at both edges in the pattern 1 for control to specify the positions of the base plate 2, and the number and position of the projecting pieces 27 are detected to judge name of the casting product. Artificial mistake is eliminated and the process control at each process and in the whole consistency can be executed.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a process control system in a foundry or the like where a wide variety of small quantities of products are produced on a daily basis.

[Conventional technology] When manufacturing a wide variety of cast products in small quantities that belong to the same family, such as valves and irregularly shaped pipes, shot blasting, heat treatment, rough finishing of the inner and outer surfaces, centering 1 machining, hydraulic testing, painting, etc. It is necessary to understand the current status of each product and constantly compare it with the schedule and make adjustments during the multi-process stage. In order to accurately identify similar products that are difficult to distinguish on the outside and to check each process, it is recommended to indicate the type by attaching a casting symbol to the surface of the cast product. General. Personnel in charge of each process read the casting symbols of the castings flowing in, record the processing status, and provide the aggregated information as basic information for process management.

[Problems to be Solved by the Invention] Cast marks on the surface of a cast product are subjected to harsh conditions such as shot blasting and heat treatment that are not found in other manufacturing processes. Therefore, the cast Roman letters and numbers tend to be unclear and can easily be misidentified when visually identified by a person in charge. Furthermore, it is inevitable that troubles will occur due to individual work errors such as forgetting to check, misunderstanding, forgetting to record, and making mistakes.

In order to eliminate such human errors, many improvements to physically reading symbols have been proposed. For example, ``A device for reading information expressed by unevenness'' (Japanese Unexamined Patent Publication No. 55-59
No. 584) and ``Method for reading uneven characters, etc.'' (Japanese Patent Laid-Open No. 57-71078), the former being optical, and the latter thermal.

The casting symbol on the surface of the casting is read using a pressure-sensitive method. It is also possible to apply barcode systems found on foods and daily necessities.

However, since these methods presuppose the use of relatively precise instruments, the processes that can be applied within a foundry are severely restricted, and cannot be equally applied to a consistent process from casting to shipping.

In particular, there are no barcodes that can withstand processes such as shot blasting and heat treatment, and optical sensors are not suitable for sophisticated equipment such as television cameras.

In order to solve the above-mentioned problems, the present invention aims to provide a foundry-specific consistent process control system that can be applied under harsh workplace conditions and prevents human error.

[Means for Solving the Problems] The casting product process control system according to the present invention is capable of identifying specific characters and numbers depending on the presence or absence of projecting pieces and the relative positional relationship of each projecting piece at a fixed position of a set of plural pieces. A promise to display is set in advance, and M stages of explants that display desired numbers based on the promise are physically placed on the base of the model that accommodates a desired plurality of groups, and the base is attached to the model body. The above problem was solved by physically reading the state of the protrusions on the surface of the cast product, converting it to the original number, and performing the desired information processing such as tabulation and recording.

[Function] For example, if you divide a square into four parts and add addresses A22Ro, H2, there is a protrusion only at address A, mouth, and C.

If you combine the presence or absence of a protrusion and its position, you can create numbers from zero to nine or A by combining the presence or absence of a protrusion and its position. .

Roman letters such as B, C, etc. can be displayed freely.

The more addresses there are in a set, the more symbols can be displayed, but
This is determined by taking into consideration the fineness of management and the amount of information required. On-site work for castings begins with the handling of wooden molds. At this stage, converting the promised symbols into addresses and transferring them onto the wooden mold is the most rational means of controlling the foundry monologue, and if this transfer is done physically, there is very little room for human error. Become. "Physical" means a technical means that utilizes the laws of nature, and specifically, as shown in the example, it is possible to electrically set a value on a base plate, which will become a template for a cast piece. It is a requirement.

Next, this entire base is attached to the specified location of the model body, such as a valve or irregularly shaped pipe, with screws, etc., and then molded and cast.
Cast-out protrusions corresponding to the combination of the explants are provided protruding from the surface. The protrusion has the same effect as, for example, filling in a single address divided into four parts, so it will disappear, be crushed, become unclear, or be overlooked during any harsh process from casting to shipping. I don't get it. Since the arrangement of each set of protrusions is physically read in each process, there is no room for human error here either. The physical means is based on electrical or magnetic means as shown in later examples, but since the object to be read is clear and simple, and there are no confusing elements, a simple proximity sensor is sufficient. The address of the protrusion that has been read is converted into numbers, Roman letters, etc., and then input as electronic information into a known device such as a personal computer and processed into the desired form.

If this single process information is unified in the central control room, all processes will be centrally managed, creating the basis for highly reliable factory operation.

[Example] FIG. 1 shows an overall perspective view of the management model 1. The model consists of a base 2 and a removably planted plant 3. FIGS. 2A and 2B are a front view and a bottom view of the explant 3. In this embodiment, it consists of a bird body 4 and a mounting leg 5. The mounting leg 5 is a thin cylindrical body divided into four parts, each with a certain gap between them. It is fixed to the bird body 4 with an elastic repulsion force. On the other hand, base 2
At a predetermined position, there is a mounting hole 6 into which the mounting leg 5 is to be inserted.
is bored, and protrusions 7 and 8 are provided at both ends, respectively. The protrusions 7 and 8 function to specify the relative position of the base 2 and other members.

A fixed position on the platform is specified by setting a single promise. Figure 3 is an example of this, where a square is divided into four parts, and each is given an address (i, 2, 2, 2, 2, etc.), and a number from 0 to 9 is assigned to this address depending on the presence or absence and placement of the explants, as shown in Table 1. Suppose you assign it. I used kanji as an example because it could be confused with the code number of the component, but of course, in practice, arithmetic numerals will be used.

The circle mark in Table 1 indicates that explants have been planted at that address. In this way, one number is displayed for each set of four explants,
For example, in FIG. 1, a four-digit serial number of 546 is displayed. Since the mounting legs 5 of the plant have elastic repulsive force, they press against the inner surface of the mounting hole 6, and will not easily come off once they are planted on the substrate. 4, Δ and B show the main body 9 of the device for physically planting the explant 3 onto the base 2, and the operation a310 electrically connected thereto. A desired number of electromagnetic cylinders 11 are provided in the main body 9 at positions corresponding to desired fixed positions.
has been set up. FIG. 5 is a partial sectional view showing only the electromagnetic cylinder 11 taken out, and is composed of an electromagnetic coil 13 that is excited by the charge from the wiring 12, and a cylinder plate 15 that slides up and down inside the cylinder case 14 due to the excitation. On the other hand, FIG. 6 shows details of the operation panel 10, and electrically shows the connection cable 16. Power cable 17. It is connected with a foreign communication cable 18, and there is a power switch 19 on the panel. Foreign switch 20.
Print switch 21. Reverse feed switch 22゜Forward feed switch 2
Push buttons displaying numbers from 3 and rOJ to "9" are lined up, a display window 24, and an opening 2 through which printing paper 25 is sent out.
There are 6.

The operation of the price device will be explained based on FIGS. 7A and 7B. Fourth
When all the cylinder plates 15 are sunk downwards as shown in Figures A and B, turn on the reverse feed switch 22 on the operation panel 10 and press the push button with the desired number. All electromagnetic coils 13a, 13d...
. . 13f is charged via the wiring 12 and an excitation effect occurs, and the cylinder plates 15a, 15d . . . 15
Only f is pushed up to the upper end of the cylinder case 14. Remaining cylinder plates 15b, 15c...15h
Since it remains sunken, the graft 3 is inserted into the hollow part formed in the cylinder case 14 with its mounting legs facing upward.

Furthermore, the base 2 of the model is placed on the main body 9 with the planting surface facing downward, and the engagement of the protrusions 7 and 8 described above is effective for this positioning. If you close the sequential switch 23 on the operation panel 10, the cylinder plate 15b whose address corresponds to the number you specified earlier.

Only 15c...15i are pushed up to push up the plant 3 on the board, and the mounting legs 5 are pushed into the mounting holes 6 and are strongly locked to the base due to the repulsive force of the mounting legs. This is the state shown in FIG. 7B, and when the base is removed from the main body, a management model implanted as shown in FIG. 1 is formed. In order to prevent human errors such as pressing the wrong button, it is also possible at this stage to check the arrangement of the explants on the base using the protrusion reader of the cast product, which will be described next, and check the returned number sequence by balancing it. .

At the operation panel 10, the numbers set are printed out on a printing paper 25, and the information is sent to the central control via a foreign communication cable.

The control model 1 assembled as shown in Fig. 1 is attached to the main body model of the cast product and molded and poured, so that the projecting piece 27 is cast in the same place on the cast product where the casting sand was dropped. appear in the state. FIG. 8 shows the entire apparatus for reading the arrangement of the protrusions and processing this into information useful for process control, and FIG. 9 is a perspective view showing the protrusions 27 being read.

In FIG. 8, this device is a reader 28. Conversion device 29
．． It has a configuration in which personal computers 30 are connected in series.

10 Δ, B, and C are three-sided views of the reading device 28, and the case 31 has a handle 32 on the top surface and a handle 32 at both ends in the longitudinal direction.
The grooves 3 into which the protrusions 7°8 on both ends of the model base fit together as described above.
3 and 34 are engraved to identify the position of the case. Inside the case, protrusion identification sensors are arranged at positions that match all the promised fixed positions.

Examples of identification sensors are shown in FIGS. 11A, B and 1.
Two embodiments are shown in Figure 2, A and B. FIG. 11 shows an electric circuit opening/closing system, including a shaft 36 that exposes a ball 35 at its tip and is fixed to the ball, a spring 37 that biases this shaft downward, and a shorting piece 38 that is fixed to its tip. Terminal 39. The signal lead wires 40 are housed in a case 41 in this order.

FIG. 11A shows the case where there is a protruding piece 27, and the ball 35
is pushed up against the biasing force, and the terminal 39 is short-circuited to electrically send a signal. On the other hand, in the case where there is no protrusion as shown in FIG. 2B, the terminals are not connected and no signal is transmitted.

FIG. 12 shows an example of a proximity sensor using magnetism, in order from the bottom: magnetic oscillation unit 42. It consists of a magnetic-voltage converter 43 and a signal lead wire 44, and is a system that converts the difference in magnetic force excited depending on the presence or absence of the protrusion 27 into a voltage difference and identifies this difference. The signal sent from the reading device 28 via the lead wire enters the converting device 29 and is converted into the original numbers or Roman letters based on the agreement, displayed on the display window, and printed out on printing paper. . In this way, the sequence of numbers for a single cast product is digitized and input into the computer 30, and using arithmetic functions, known information processing such as aggregation, comparison of forecast and actual results, warnings, warnings, etc. Provides the basis for process control.

[Effects of the Invention] As stated above, the process control system for cast products according to the present invention is a completely new system that focuses on various processes unique to foundries, so it cannot be applied to other general industries. It also achieved automation of management, which was not applicable in the foundry industry. The conventional confusion caused by human error, the confusion of information due to arbitrary records of each individual, and the difficulty of understanding the whole thing will all disappear, and the system will create a perfect network for consistent management of each process and the whole.

Secondly, it greatly reduces the actual work of personnel in unavoidable working environments such as high heat, dust, and noise.
If combined with Haku's methods, unmanned operation is not impossible. It deserves high praise as a trump card that will bring the lagging management systems of all foundries forward all at once.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a management model in an embodiment of the present invention;
Figures 2A and BI are front and bottom views, Figure 3 is an example of the fixed position, and Figures 4A, B, and C are a plan view, side sectional view, and front (partial) of the planting device. 5 is a front sectional view of the electromagnetic cylinder, 6 is a front view of the operation panel, and 7 is a sectional view.
Figures A and B are front (partial) cross-sectional views explaining the operation of the implantation device, Figure 8 is a perspective view of the information processing means, Figure 9 is a perspective view of the cast product to be read, Figure 10A, B and C are a plan view, a front sectional view, a side sectional view, and FIG. 11A of the reading device. 27... Projection piece, 28... Reading device 30
······computer

Claims (1)

[Claims] A promise is set in advance to display specific letters and numbers depending on the presence or absence of protrusions protruding from a set of fixed positions and their relative positions, and the display is displayed on the base of the model that accommodates the desired multiple sets. Based on the above agreement, we physically implant the explants that display the desired letters and numbers, attach the base to the model body, and cast the mold into the mold, and then check the condition of the protrusions on the surface of the cast product. A casting process control system that physically reads the information, converts it to the original characters and numbers, and performs the desired information processing such as tabulation and recording.