US20180326475A1 - Device and method that can detect misalignment between cope and drag - Google Patents

Device and method that can detect misalignment between cope and drag Download PDF

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Publication number
US20180326475A1
US20180326475A1 US15/777,313 US201615777313A US2018326475A1 US 20180326475 A1 US20180326475 A1 US 20180326475A1 US 201615777313 A US201615777313 A US 201615777313A US 2018326475 A1 US2018326475 A1 US 2018326475A1
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United States
Prior art keywords
drag
cope
measuring distances
misalignment
measuring
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Abandoned
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US15/777,313
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English (en)
Inventor
Tsuyoshi Sakai
Tokiya Terabe
Yasuhito SUGANUMA
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Sintokogio Ltd
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Sintokogio Ltd
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Assigned to SINTOKOGIO, LTD. reassignment SINTOKOGIO, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SAKAI, TSUYOSHI, SUGANUMA, Yasuhito, TERABE, TOKIYA
Publication of US20180326475A1 publication Critical patent/US20180326475A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C11/00—Moulding machines characterised by the relative arrangement of the parts of same
    • B22C11/12—Moulding machines able to travel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C19/00—Components or accessories for moulding machines
    • B22C19/04—Controlling devices specially designed for moulding machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C11/00—Moulding machines characterised by the relative arrangement of the parts of same
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C11/00—Moulding machines characterised by the relative arrangement of the parts of same
    • B22C11/02—Machines in which the moulds are moved during a cycle of successive operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/20—Stack moulds, i.e. arrangement of multiple moulds or flasks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D45/00—Equipment for casting, not otherwise provided for

Definitions

  • the present invention relates to a device and a method that can detect any misalignment between a cope and a drag that have been manufactured by means of a flaskless molding machine and that have then been assembled.
  • the present invention has been developed to solve this problem.
  • the objective of it is to provide a device and a method that can detect, before pouring starts, any misalignment between a cope and a drag that have been manufactured by means of a flaskless molding machine and that have then been assembled.
  • a device that can detect any misalignment between a cope and a drag of a first aspect of the present invention is, as shown in FIGS. 1, 2, and 3 , for example, a device 40 that can detect any misalignment between a cope 2 and a drag 3 that have been manufactured by means of a flaskless molding machine 1 and assembled and that are being transported to a position for pouring.
  • the device 40 comprises a plurality of means 51 , 52 , and 53 for measuring distances to the cope and the drag that measure distances to the cope 2 and the drag 3 .
  • It also comprises a means 48 for calculating a degree of a misalignment between the cope and the drag that calculates a degree of a misalignment between the cope 2 and the drag 3 on a basis of the distances to the cope 2 and the drag 3 as measured by the means 51 , 52 , and 53 for measuring distances to the cope and the drag.
  • the three means 51 , 52 , 53 for measuring distances to the cope and the drag are caused by the means 46 for moving up and down to move to a level for measuring the cope 2 and to a level for measuring the drag 3 .
  • the device that can detect any misalignment between the cope and. the drag of a third aspect of the present invention is the device 40 of the second aspect, wherein the cope 2 and the drag 3 are rectangular in each horizontal section.
  • the three means 51 , 52 , 53 for measuring distances to the cope and the drag are a first means 51 for measuring distances to the cope and the drag, a second means 52 for measuring distances to the cope and the drag, and a third means 53 for measuring distances to the cope and the drag.
  • the first means 51 for measuring distances to the cope and the drag measures the distances to the points 2 i, 3 i, which are on first sides 2 a, 3 a of the cope and drag, which sides are parallel to a conveying direction 7 , respectively.
  • the second means 52 for measuring distances to the cope and the drag measures the distances to the points 2 j, 3 j, which are spaced apart from the points 2 i, 3 i on the first sides 2 a, 3 a by a predetermined distance in the horizontal direction, respectively.
  • the third means 53 for measuring distances to the cope and the drag measures the distances to the points 2 k, 3 k , which are on second sides 2 b, 3 b of the cope and drag, which sides are perpendicular to the conveying direction 7 , respectively.
  • the device that can detect any misalignment between the cope and the drag of a fourth aspect of the present invention, as in FIGS. 1, 2, and 3 , for example, is the device 40 of the third aspect, wherein the first means 51 for measuring distances to the cope and the drag, the second means 52 for measuring distances to the cope and the drag, and the third means 53 for measuring distances to the cope and the drag, are laser-type displacement sensors.
  • the first, second, and third means for measuring distances to the cope and the drag are laser-type displacement sensors, the distances to the points of the cope and drag are reliably measured by means of non-contact sensors.
  • a method that can detect any misalignment between the cope and the drag of a fifth aspect of the present invention, as in FIGS. 1-5 , for example, is a method to use the device 40 of the third aspect.
  • the method comprises a step of moving the first means 51 for measuring distances to the cope and the drag, the second means 52 for measuring distances to the cope and the drag, and the third means 53 for measuring distances to the cope and the drag to a level to measure the cope 2 by the means 46 for moving up and down. It also comprises a step of measuring a distance S 11 to the point 2 i on the first side 2 a of the cope by the first means 51 for measuring distances to the cope and the drag.
  • It also comprises a step of measuring a distance S 12 to the point 2 j on the first side 2 a of the cope by the second means 52 for measuring distances to the cope and the drag. It also comprises a step of measuring a distance S 13 to the point 2 k on the second side 2 b of the cope by the third means 53 for measuring distances to the cope and the drag.
  • It also comprises a step of calculating a position in a horizontal plane and an angle of rotation in a horizontal direction of the cope 2 by the means 48 for calculating a degree of a misalignment between the cope and the drag based on the distance S 11 to the point 2 i on the first side 2 a of the cope measured by the first means 51 for measuring distances to the cope and the drag, the distance S 12 to the point 2 j on the first side 2 a of the cope measured by the second means 52 for measuring distances to the cope and the drag, and the distance S 13 to the point 2 k on the second side 2 b of the cope measured by the third means 53 for measuring distances to the cope and the drag.
  • It also comprises a step of measuring a distance S 23 to the point 3 k on the second side 3 b of the drag by the third means 53 for measuring distances to the cope and the drag. It also comprises a step of calculating a position in a horizontal plane and an angle of rotation in a horizontal direction of the drag 3 by the means 48 for calculating a degree of a misalignment between the cope and the drag based on the distance S 21 to the point 3 i on the first side 3 a of the drag measured by the first means 51 for measuring distances to the cope and the drag, the distance S 22 to the point 3 j on the first side 3 a of the drag measured by the second means 52 for measuring distances to the cope and the drag, and the distance S 23 to the point 3 k on the second side 3 b of the drag measured by the third means 53 for measuring distances to the cope and the drag.
  • It also comprises a step of calculating a degree of a misalignment based on the positions in the horizontal plane and the angles of rotation in the horizontal direction of the cope 2 and the drag 3 that have been calculated. It also comprises a step of determining that a misalignment has occurred if the degree of misalignment is outside of a predetermined allowable range. By this configuration a misalignment can be determined based on the correct degree of misalignment that has been detected.
  • the method that can detect any misalignment between the cope and the drag of a sixth aspect of the present invention is the method of the fifth aspect, wherein no molten metal is poured into the cope and the drag that have been determined to have a misalignment.
  • the method that can detect any misalignment between the cope and the drag of a seventh aspect of the present invention is the method of the fifth aspect, wherein if a misalignment is determined to have occurred., then a molding operation by the flaskless molding machine 1 is stopped.
  • a molding operation by the flaskless molding machine can be stopped until the causes of any misalignment are resolved, consumption of molding sand due to useless molding can be prevented.
  • the method that can detect any misalignment between the cope and the drag of an eighth aspect of the present invention is the method of the fifth aspect, wherein if a misalignment is determined to have occurred, then a cause of the misalignment is identified and displayed based on an appearance of the misalignment.
  • the method that can detect any misalignment between the cope and the drag of a ninth aspect of the present invention is the method of the fifth aspect, wherein if a misalignment is determined to have occurred then a cause of the misalignment is identified based on an appearance of the misalignment, so that conditions for operating the device that is the cause of the misalignment are adjusted.
  • the method that can detect any misalignment between the cope and the drag of a tenth aspect of the present invention is the method of the fifth aspect, wherein if no misalignment is determined to have occurred, then data are stored that show that no misalignment has occurred in the flaskless molding machine 1 or a molding line 30 that conveys the cope 2 and the drag 3 from the flaskless molding machine 1 to a position for pouring.
  • the data that show that no misalignment has occurred in the flaskless molding machine or the molding line are stored it can be confirmed that no problem due to a misalignment has occurred during molding.
  • the method that can detect any misalignment between the cope and the drag of an eleventh aspect of the present invention is the method of the fifth aspect, wherein data on the positions in the horizontal plane and the angle of rotation in the horizontal direction of the cope and the drag that have been calculated and data on the degree of misalignment that has been calculated are stored.
  • the method that can detect any misalignment between the cope and the drag of a twelfth aspect of the present invention is the method of the fifth aspect, wherein if the degree of misalignment is within the allowable range, but not within a warning range, which is smaller than an allowable range, a predictor of a misalignment is displayed.
  • the device that can detect any misalignment between the cope and the drag of a thirteenth aspect of the present invention, as in FIGS. 4, 5, and 6 , for example, is the device 60 of the first aspect, wherein the cope 2 and the drag 3 are rectangular in each horizontal section.
  • the plurality of means 71 , 72 , 73 , 74 , 75 , 76 for measuring distances to the cope and the drag are a first means 71 for measuring distances to the cope, a second means 72 for measuring distances to the cope, a third means 73 for measuring distances to the cope, a first means 74 for measuring distances to the drag, a second means 75 for measuring distances to the drag, and a third means 76 for measuring distances to the drag.
  • the first means 71 for measuring distances to the cope measures the distance S 11 to the point 2 i, which is on a first side 2 a of the cope, which side is parallel to a direction for conveying the cope 2 and the drag 3 .
  • the second means 72 for measuring distances to the cope measures the distance S 12 to the point 2 j, which is spaced apart from the point 2 i on the first side 2 a of the cope by a predetermined distance in the horizontal direction.
  • the third means 73 for measuring distances to the cope measures the distance S 13 to the point 2 k, which is on a second side 2 b of the cope, which side is perpendicular to the direction for conveying the cope 2 and the drag 3 .
  • the first means 74 for measuring distances to the drag measures the distance S 21 to the point 3 i, which is on a first side 3 a of the drag, which side is parallel to the direction for conveying the cope 2 and the drag 3 .
  • the second means 75 for measuring distances to the drag measures the distance S 22 to the point 3 j, which is spaced apart from the point 3 i on the first side 3 a of the drag by a predetermined distance in the horizontal direction.
  • the third means 76 for measuring distances to the drag measures the distance S 23 to the point 3 k, which is on a second side 3 b of the drag, which side is perpendicular to the direction for conveying the cope 2 and the drag 3 .
  • the device that can detect any misalignment between the cope and the drag of a fourteenth aspect of the present invention, as in FIGS. 7 and 8 , for example, is the device 5 of the first aspect, wherein the cope 2 and the drag 3 are rectangular in each horizontal section.
  • the plurality of means 8 , 9 , 11 , 12 for measuring distances to the cope and the drag are a first means 8 for measuring distances to the cope, a first means 9 for measuring distances to the drag, a second means 11 for measuring distances to the cope, and a second means 12 for measuring distances to the drag.
  • the first means 8 for measuring distances to the cope measures a distance to a first side 2 a of the cope, which side is parallel to the direction for conveying the cope 2 .
  • the first means 9 for measuring distances to the drag measures a distance to a first side 3 a of the drag, which side is parallel to the direction for conveying the drag 3 .
  • the second means 11 for measuring distances to the cope measures a distance to a second side 2 b of the cope, which side is perpendicular to the direction for conveying the cope 2 .
  • the second means 12 for measuring distances to the drag measures a distance to a second side 3 b of the drag, which side is perpendicular to the direction for conveying the drag 3 .
  • the device that can detect any misalignment between the cope and the drag of a fifteenth aspect of the present invention, as in FIGS. 7 and 8 , for example, is the device 5 of the fourteenth aspect, wherein the first means 8 for measuring distances to the cope and the first means 9 for measuring distances to the drag are configured to be moved by means of an actuator 10 in the direction for conveying the cope 2 and the drag 3 .
  • the second means 11 for measuring distances to the cope and the second means 12 for measuring distances to the drag are configured to be moved by means of an actuator 13 in a direction perpendicular to the direction for conveying the cope 2 and the drag 3 .
  • the first means for measuring the distance to the cope and the first means for measuring the distance to the drag, and the second means for measuring the distance to the cope and the second means for measuring the distance to the drag move by the actuators in the directions that are parallel to the sides to be measured, the distances can be continually measured at any interval along the sides of the cope and the drag.
  • a lot of data for determining any alignment can be obtained so that any misalignment can be reliably detected.
  • the device that can detect any misalignment between the cope and the drag of a sixteenth aspect of the present invention, as in FIGS. 7 and. 8 , for example, is the device 5 of the fourteenth aspect, wherein the first means 8 for measuring distances to the cope, the first means 9 for measuring distances to the drag, the second means 11 for measuring distances to the cope, and the second means 12 for measuring distances to the drag, are configured to be able to be simultaneously moved up and down by an actuator 15 .
  • an actuator 15 By this configuration, a vertical adjustment of the means for measuring distances can he achieved within a short period of time.
  • the device that can detect any misalignment between the cope and the drag of a seventeenth aspect of the present invention, as in FIGS. 7 and 8 , for example, is the device 5 of the fourteenth aspect, wherein the first means 8 for measuring distances to the cope, the first means 9 for measuring distances to the drag, the second means 11 for measuring distances to the cope, and the second means 12 for measuring distances to the drag, are laser-type displacement sensors.
  • the first means for measuring distances to the cope, the first means for measuring distances to the drag, the second means for measuring distances to the cope, and the second means for measuring distances to the drag are laser-type displacement sensors, the distances are reliably measured by means of non-contact sensors.
  • a method that can detect any misalignment between the cope and the drag of an eighteenth aspect of the present invention, as in FIGS. 7-11 , for example, is a method to use the device 5 of the fourteenth aspect.
  • the method comprises a step of measuring a distance S 1 to a first side 2 a of the cope by the first means 8 for measuring distances to the cope. It also comprises a step of measuring a distance S 2 to a first side 3 a of the drag by the first means 9 for measuring distances to the drag. It also comprises a step of measuring a distance 53 to a second side 2 b of the cope by the second means 11 for measuring distances to the cope.
  • the method that can detect any misalignment between the cope and the drag of a nineteenth aspect of the present invention, as in FIGS. 7-11 , for example, is the method of the eighteenth aspect, wherein the first means 8 for measuring distances to the cope and the first means 9 for measuring distances to the drag are configured to be moved by means of an actuator 10 in the direction for conveying the cope 2 and the drag 3 .
  • the second means 11 for measuring distances to the cope and the second means 12 for measuring distances to the drag are configured to be moved by means of an actuator 13 in a direction perpendicular to the direction for conveying the cope 2 and the drag 3 .
  • the method that can detect any misalignment between the cope and the drag of a twelfth aspect of the present invention, as in FIGS. 7-11 , for example, is the method of the eighteenth aspect, wherein no molten metal is poured into the cope 2 and the drag 3 that have been determined to have a misalignment.
  • FIG. 1 is a schematic drawing that shows a plan view of the device that can detect any misalignment between a cope and a drag.
  • the device is an embodiment of the present invention.
  • FIG. 2 is a view taken along the arrow A-A in FIG. 1 .
  • FIG. 3 is a view taken along the arrow B-B in FIG. 1 .
  • FIG. 4 is a schematic drawing that illustrates a measurement of a distance to a side of a cope.
  • FIG. 5 is a schematic drawing that illustrates a measurement of a distance to a side of a drag.
  • FIG. 6 is a side view of the device that can detect any misalignment between a cope and a drag.
  • the device is a modification of the device as in FIG. 1 .
  • FIG. 7 is a schematic drawing that shows a plan view of the device that can detect any misalignment between a cope and a drag.
  • the device is another embodiment of the present invention.
  • FIG. 8 is a view taken along the arrow A-A in FIG. 7 .
  • FIG. 9 is a view taken along the arrow B-B in FIG. 7 .
  • FIG. 10 is a schematic drawing that illustrates a measurement of a distance to a side of a cope and a drag. The side is perpendicular to a direction to convey the cope and the drag.
  • FIG. 11 is a schematic drawing that illustrates a measurement of a distance to a side of a cope and a drag. The side is parallel to a direction to convey the cope and the drag.
  • the reference number “1” denotes a flaskless molding machine.
  • the flaskless molding machine 1 is a following molding machine. After molding a cope and a drag by using molding sand (green sand in this embodiment), the cope and the drag are assembled. Then the cope and the drag are extracted from upper and lower flasks to be carried out of the molding machine.
  • the cope 2 and the drag 3 that have been carried out of the flaskless molding machine 1 in the direction shown by the arrow 6 are mounted on a bogie 4 with a molding board.
  • the cope 2 and the drag 3 that have been mounted on the bogie 4 with a molding board are intermittently conveyed in the direction shown by the arrow 7 (the conveying direction of the cope 2 and the drag 3 ) by a distance that equals the length of a mold, i.e., a pitch, by a means for conveying (a pusher and a cushion), which is not shown.
  • the bogie 4 with a molding board travels on a rail 20 that is supported by a frame 22 .
  • a device 40 that can detect any misalignment between the cope 2 and the drag 3 is provided.
  • the details of the device 40 that can detect any misalignment between the cope and the drag (hereafter, “device 40 ”), which is a first embodiment of the present invention, are discussed.
  • the direction for conveying the cope 2 and the drag 3 is called a Y-direction
  • the direction perpendicular to the direction for conveying the cope 2 and the drag 3 is called an.
  • X-direction the vertical direction is called a Z-direction.
  • the device 40 has three means 51 , 52 , 53 for measuring distances to the cope and the drag (hereafter, “means 51 , 52 , 53 ”) that are arranged along the direction (the Y-direction) for conveying the cope 2 and the drag 3 .
  • the three means 51 , 52 , 53 are mounted on a frame 44 for moving up and down that extends along the Y-direction.
  • the frame 44 for moving up and down moves up and down by means of a cylinder 46 , i.e., an actuator.
  • the cylinder 46 is supported by a supporting frame 42 that stands on a base.
  • the cylinder 46 i.e., the actuator
  • the actuator can be any type, such as an electric type, an oil-pressure type, a water-pressure type, or an air-pressure type.
  • the actuator is not limited to the cylinder 46 , but may be any known means, such as trapezoidal thread forms or a pantograph.
  • the supporting frame 42 does not need to stand on the base, but may be fixed to the frame 22 .
  • the frame 44 for moving up and down is a beam that is nearly as long as the cope 2 and the drag 3 in the Y-direction.
  • the first means 51 is mounted on the part of the frame 44 for moving up and down that is near the back end in the direction for conveying the cope 2 and the drag 3 . It measures distances to the points 2 i, 3 i on the first sides 2 a , 3 a, which are parallel (the Y-direction) to the direction for conveying the cope 2 and the drag 3 .
  • the second means 52 is mounted on the front part of the frame 44 for moving up and down in the direction for conveying the cope 2 and the drag 3 . It measures distances to the points 2 j, 3 j on the first sides 2 a, 3 a.
  • the points 2 j, 3 j are located on the same level as the points 21 , 31 and spaced apart from them by a predetermined distance.
  • the predetermined distance is the horizontal distance by which the locations of the centers and the angles of rotations of the cope 2 and the drag 3 can be appropriately calculated based on the positions of the three points, as discussed below.
  • the third means 53 is mounted on the part of the frame 44 for moving up and down that is near the front end in the direction for conveying the cope 2 and the drag 3 . It measures distances to the points 2 k, 3 k on the second sides 2 b, 3 b, which are perpendicular (the X-direction) to the direction for conveying the cope 2 and the drag 3 .
  • the points 2 k, 3 k are located on the same level as the points 2 i, 3 i and the points 2 j, 3 j.
  • the first means 51 and the second means 52 preferably face the direction (the X-direction) that is perpendicular to the direction of the frame 44 for moving up and down (the Y-direction), to measure the distances to the points 2 i, 3 i, 2 j, 3 j on the first sides 2 a , 3 a , which sides are parallel to the frame 44 for moving up and clown.
  • the third means 53 faces diagonally to measure the distances to the points 2 k , 3 k on the second sides of 2 b, 3 b. These sides are perpendicular to the frame 44 for moving up and down.
  • the distances to three points can be measured. These points are positioned on a horizontal plane (not on a line). These means are arranged along what is almost a line on the frame 44 for moving up and down. Further, the device 40 does not obstruct the cope 2 or the drag 3 that are being transported.
  • the first, second, and third means 51 , 52 , 53 move up and down.
  • the first, second, and third means 51 , 52 , 53 are moved up and down to a set height to measure the points 2 i, 2 j, 2 k of the cope 2 and to a set height to measure the points 3 i, 3 j, 3 k of the drag 3 .
  • the positions of a total of six points, i.e., three points on the cope 2 and three points on the drag 3 can be measured by three means 51 , 52 , 53 .
  • the points 2 i, 2 j, 2 k of the cope 2 and the points 3 i , 3 j, 3 k of the drag 3 are positioned at a predetermined distance from a parting plane 19 between the cope 2 and the drag 3 .
  • the predetermined distance for the points 2 i, 2 j, 2 k of the cope 2 may be the same as, or different from, that for the points 3 i, 3 j, 3 k of the drag 3 .
  • the points 2 i, 2 j , 2 k are positioned at a level that is 100 mm higher than the parting plane 19 .
  • the points 3 i, 3 j, 3 k are positioned at a level that is 100 mm lower than the parting plane 19 .
  • the distance from the upper surface of the bogie 4 with a molding board to the parting plane 19 equals the height of the drag 3 .
  • the height of the drag 3 is measured for each drag 3 that has been molded by the flaskless molding machine 1 .
  • the device 40 measures the distances, the height is then known.
  • the shapes of the cope 2 and the drag 3 that are molded by the flaskless molding machine 1 are known. Once the positions of the points 2 i, 2 j, 2 k are known, then the location of the center of, and the angle of the horizontal rotation of, the cope 2 , can be calculated. Thus, if the cross-section of it is rectangular, then the coordinates of the four corners can be calculated. In the same way, once the positions of the points 3 i, 3 j, 3 k are known, the location of the center of, and the angle of the horizontal rotation of, the drag 3 , can be calculated. Thus, if the cross-section of it is rectangular, the coordinates of the four corners can be calculated.
  • the cope 2 and the drag 3 are horizontally mounted on the bogie 4 with a molding board. Any misalignment between the cope 2 and the drag 3 can be determined based on the locations of the centers and the angles of the horizontal rotations, or the coordinates of the four corners, which are discussed above. The locations of the centers and the angles of the horizontal rotations, or the coordinates of the four corners, are calculated by the means 48 for calculating the degree of a misalignment between the cope and the drag (hereafter, “the means 48 for calculating”).
  • the means 48 for calculating may be provided in the device 40 as a dedicated means for calculating the degree of a misalignment between the cope and the drag.
  • the means 48 for calculating may be a controller.
  • laser-type displacement sensors are used for the first, second, and third means 51 , 52 , 53 . Since they are laser-type displacement sensors, the measurements are accurate, without any contact being made with the cope 2 or the drag 3 . Further, they are compact. However, these means are not limited to the laser-type displacement sensors, but may be any known displacement sensors, such as ultrasonic displacement sensors and contact displacement sensors.
  • the cope 2 and the drag 3 that have been molded by the flaskless molding machine 1 are mounted on the bogie 4 with a molding board at a station 17 for carrying a mold in.
  • the cope 2 and the drag 3 that have been mounted on the bogie 4 with a molding board are intermittently conveyed on the molding line 30 .
  • the cope 2 and the drag 3 that are intermittently conveyed are carried into a station 18 for detecting a misalignment, namely, they stop at a position that is predetermined in relation to the device 40 , the device 40 operates to detect any misalignment.
  • the words “stop at a position that is predetermined in relation to the device 40 ” mean to stop at a position where the first, second, and third means 51 , 52 , 53 of the device 40 can easily measure the distances to the three points 2 i, 2 j, 2 k of the cope 2 and to the three points 3 i, 3 j, 3 k of the drag 3 . That is, the position where the cope 2 and the drag 3 that are intermittently conveyed temporarily stop is not just beside the device 40 , but slightly shifts forward or backward. Because of this the third means 53 can measure the distances to the points 2 k, 3 k on the second sides 2 b, 3 b.
  • the bogie 4 with a molding board that is carried into the station 18 for detecting a misalignment is preferably fixed by a clamp (not shown) so as not to move. Any error in measuring the distances by means of the device 40 , that is caused by a shake of the bogie 4 with a molding board can be prevented.
  • the device 40 first adjusts, by means of the cylinder 46 , the level of the frame 44 for moving up and down to a level for measuring the distances to the three points 2 i, 2 j, 2 k of the cope 2 . Namely, it adjusts the level to the predetermined level above the parting plane 19 . Then the first means 51 measures the distance S 11 to the point 2 i, the second means 52 measures the distance S 12 to the point 2 j, and the third means 53 measures the distance S 13 to the point 2 k. The measured distances S 11 , 512 , S 13 are sent to the means 48 for calculating. The means 48 for calculating calculates the horizontal location of the center and the angle of rotation of the cope 2 .
  • the level of the frame 44 for moving up and down is adjusted by means of the cylinder 46 to a level for measuring the distances to the three points 3 i, 3 j, 3 k of the drag 3 .
  • the first means 51 measures the distance S 21 to the point 3 i
  • the second means 52 measures the distance S 22 to the point 3 j
  • the third means 53 measures the distance S 23 to the point 3 k.
  • the operations up to these measurements are carried out while the cope 2 and the drag 3 stop while being intermittently conveyed.
  • the measured distances S 21 , S 22 , S 23 are sent to the means 48 for calculating.
  • the means 48 for calculating calculates the horizontal location of the center and the angle of rotation of the drag 3 .
  • the level of the frame 44 for moving up and down may be adjusted to a level for measuring the distances to the three points 2 i, 2 j, 2 k of the cope 2 , so that, the first, second, and third means 51 , 52 , 53 measure the distances S 11 , S 12 , S 13 to the points 2 i, 2 j, 2 k, respectively.
  • the first, second, and third means 51 , 52 , 53 can measure in any order or at the same time. In the present application documents, the order of steps is arbitrary. So the steps may be carried out in any order or at the same time, except for any step that is discussed by using a word that defines a sequence, e.g., “after,” or except when the sequence is obvious from the context.
  • the means 48 for calculating calculates the coordinates of the respective four corners of rectangles based on the locations of the centers and the angles of rotations of the cope 2 and the drag 3 . It calculates the horizontal distances between corresponding corners of the cope 2 and the drag 3 .
  • a misalignment is determined based on the horizontal distances between corresponding corners of the cope 2 and the drag 3 that have been calculated by the means 48 for calculating. For example, when an allowable range for horizontal distances is 0.5 mm or less, the allowable range is 0 to 0.5 mm. The misalignment is determined by seeing if the horizontal distances of the four corners are within the allowable range. This operation for determining may be carried out by a dedicated means for calculating a degree of a misalignment between the cope and the drag of the device 40 or by a controller for another device. If the distance at any of the four corners exceeds the allowable range, then a misalignment may be determined to have occurred.
  • a misalignment may be determined to have occurred if the distances at two or three or all four corners exceed the allowable range. Alternatively, if the average or the root-mean-square of the four distances exceeds the allowable range, then a misalignment may be determined to have occurred. Alternatively, the misalignment may be determined to have occurred on the basis of the differences in the locations of the centers and the angles of rotations. The result of determining a misalignment is sent to the controller of the molding line 30 , the pouring machine (not shown), or the like.
  • the clamp on the bogie 4 with a molding board is released and the cope 2 and the drag 3 are again intermittently conveyed.
  • a jacket (not shown) is capped on the cope 2 and the drag 3 and a weight is placed on them before pouring starts.
  • molten metal is poured into the cope 2 and the drag 3 by the pouring machine (not shown).
  • the operation for determining a misalignment by the device 40 may be carried out after the jacket is capped or after the weight is placed on it.
  • the misalignment is determined to have occurred by measuring the distances to the respective three points 2 i, 2 j, 2 k, and 3 i, 3 j, 3 k of the cope 2 and the drag 3 from the first, second, and third means 51 , 52 , 53 of the device 40 .
  • the first, second, and third means 51 , 52 , 53 are mounted on the frame 44 for moving up and down that is spaced apart from the cope 2 and the drag 3 by a predetermined distance.
  • the measurement can be performed after the jacket is capped.
  • a misalignment is determined to have occurred as a result of detecting a misalignment, preferably no molten metal is poured into the cope 2 and the drag 3 that have a misalignment.
  • the controller of the pouring machine is set not to pour molten metal into the cope 2 and the drag 3 that have the misalignment. Since no molten metal is poured into the cope 2 and the drag 3 that have the misalignment, consuming molten metal by useless pouring can he prevented.
  • molding by the flaskless molding machine 1 is preferably stopped. Namely, until the causes of the misalignment are resolved, molding by the flaskless molding machine 1 is stopped. Since molding the cope 2 and the drag 3 that may have a misalignment can be avoided, consuming the molding sand by useless molding can be prevented.
  • the wording “molding by the flaskless molding machine 1 is stopped” just means that no mold is molded. The flaskless molding machine 1 may operate so that no mold is molded. Or the flaskless molding machine 1 may be deactivated so that only the molding line 30 may operate.
  • the cause of the misalignment, to be displayed is preferably identified based on the appearance of the misalignment. For example, if the cope 2 is displaced backwards relative to the drag 3 , namely, in the direction that the flaskless molding machine 1 pushes a mold out (the arrow 6 in FIG. 1 ), the initial velocity for pushing the drag 3 out by means of a device for pushing a mold out (not shown) may be too fast. If the cope 2 is displaced backwards relative to the drag 3 , namely, in the direction that the molding line 30 conveys the cope 2 and drag 3 (the arrow 7 in FIG.
  • the initial velocity for pushing the bogie 4 with a molding board by means of a pusher may be too fast.
  • the causes of the misalignment can be predicted based on the direction of the misalignment between the cope 2 and the drag 3 .
  • the causes of the misalignment may be displayed on a display panel of the device 40 , a dedicated display panel, or a controller for another device.
  • the cause of the misalignment is preferably identified based on the appearances of the misalignment, so that the operating condition of the device that causes the misalignment is preferably modified.
  • the cope 2 is displaced backwards relative to the drag 3 , namely, in the direction toward which the flaskless molding machine 1 pushes a mold out (the arrow 6 in FIG. 1 )
  • the initial velocity for pushing the drag 3 out by means of a device for pushing a mold out may be too fast.
  • the initial velocity of the device for pushing a mold out which is the operating condition that causes the misalignment, is modified.
  • the initial velocity of the device for pushing a mold out is automatically or manually modified to be decreased. In this way the misalignment is prevented from occurring in the following cycles.
  • the cope 2 is displaced backwards relative to the drag 3 , namely, in the direction toward which the molding line 30 conveys the cope 2 and drag 3 (the arrow 7 in FIG. 1 )
  • the initial velocity for pushing the bogie 4 with a molding board by means of a pusher may be too fast.
  • the initial velocity of the pusher which is the operating condition that causes the misalignment, is modified.
  • the initial velocity of the pusher is automatically or manually modified, to be decreased. In this way the misalignment is prevented from occurring in the following cycles.
  • data are preferably stored that show that no misalignment has been caused by the flaskless molding machine 1 or the molding line 30 , which conveys the cope 2 and the drag 3 from the flaskless molding machine 1 to the position for pouring.
  • the data may be stored in the means 48 for calculating or in a controller for another device.
  • the data on the positions in the horizontal plane and the angle of rotation in the horizontal direction of the cope 2 and the drag 3 that have been calculated by the means 48 for calculating and the data on the calculated degree of misalignment are preferably stored. Since the data on the positions in the horizontal plane and the angle of rotation in the horizontal direction of the cope 2 and the drag 3 and the data on the calculated degree of misalignment are stored in this way, any change in the degree of misalignment can be found. Thus data that are useful to investigate the cause of a misalignment and to maintain the flaskless molding machine 1 and the molding line 30 can be accumulated.
  • the data may be stored in the means 48 for calculating or in a controller for another device.
  • the degree of misalignment between the cope 2 and the drag 3 that has been calculated by the means 48 for calculating is within the preset allowable range, it may not be within a warning range, which is set to be smaller than the allowable range.
  • a predictor of a misalignment is preferably displayed. If a predictor is displayed, the operating condition that can cause the misalignment between the cope 2 and the drag 3 can be modified before a defect occurs. Thus any possible waste caused by a defect can be prevented.
  • the predictor of a misalignment may be displayed on a display panel of the device 40 , a dedicated display panel, or a controller for another device.
  • the device 60 that can detect any misalignment between the cope and the drag (hereafter, “the device 60 ”), which is a second embodiment, is discussed in detail. About the device 60 , only the points that differ from the device 40 are discussed.
  • the device 60 has a first means 71 for measuring distances to the cope, a second means 72 for measuring distances to the cope, a third means 73 for measuring distances to the cope, a first means 74 for measuring distances to the drag, a second means 75 for measuring distances to the drag, and a third means 76 for measuring distances to the drag, to measure the distances to the points 2 i, 2 j on the first side 2 a of the cope 2 , the distance to the point 2 k on the second side 2 b of the cope 2 , the distances to the points 3 i, 3 j on the first side 3 a of the drag 3 , and the distance to the point 3 k on the second side 3 b of the drag 3 .
  • the first means 71 for measuring distances to the cope, the second means 72 for measuring distances to the cope, and the third means 73 for measuring distances to the cope, are mounted on a horizontal frame 64 at positions that are suitable to measure the distances to the points 2 i, 2 j, 2 k of the cope 2 .
  • the first means 74 for measuring distances to the drag, the second means 75 for measuring distances to the drag, and the third means 76 for measuring distances to the drag are mounted on a horizontal frame 66 at positions that are suitable to measure the distances to the points 3 i, 3 j, 3 k of the drag 3 .
  • the two horizontal frames 64 , 66 are fixed to the supporting frame 62 . Namely, they are not moved up and down by an actuator.
  • the device 60 since three points of the cope 2 and three points of the drag 3 , namely, a total of six points, are measured by the six means 71 - 76 for measuring distances to the cope and the drag, the locations of the centers and the angles of rotations of the cope 2 and the drag 3 are determined without vertically moving the means for measuring distances to the cope and the drag. Thus the degree of misalignment can be quickly and accurately detected. Further, as no actuator vertically moves a frame for moving up and down, the six means 71 - 76 for measuring distances to the cope and the drag can measure the distances to the points 2 i, 2 j, 2 k, 3 i, 3 j, 3 k of the cope 2 and the drag 3 at the same time. Thus the period of time for operating the device 60 can be shortened.
  • the device 5 has a first means 8 for measuring distances to the cope (hereafter, “the first means 8 for measuring”) that measures the distances to the first side 2 a of the cope, which side is parallel to the Y-direction. It also has a first means 9 for measuring distances to the drag (hereafter, “the first means 9 for measuring”) that measures the distances to the first side 3 a of the drag, which side is parallel to the Y-direction.
  • the first means 8 for measuring and the first means 9 for measuring are configured to move in the Y-direction by means of a first cylinder 10 , i.e., an actuator.
  • the device 5 also has a second means 11 for measuring distances to the drag (hereafter, “the second means 11 for measuring”) that measures the distances to the second side 2 b of the drag, which side is parallel to the X-direction. It also has a second means 12 for measuring distances to the drag (hereafter, “the second means 12 for measuring”) that measures the distances to the second side 3 b of the drag, which side is parallel to the X-direction.
  • the second means 11 for measuring and the second means 12 for measuring are configured to move in the X-direction by means of a second cylinder 13 , i.e., an actuator.
  • the first cylinder 10 and the second cylinder 13 are attached to a common frame 14 for moving up and down (see FIG. 8 ).
  • the frame 14 for moving up and down is configured to move in the Z-direction by means of a third cylinder 15 , i.e., an actuator. Namely, it can be moved up and down.
  • the third cylinder 15 is attached to a supporting frame 16 .
  • the supporting frame 16 stands on a base 21 .
  • the laser-type displacement sensors are used for the first means 8 for measuring, the first means 9 for measuring, the second means 11 for measuring, and the second means 12 for measuring.
  • the electric cylinders are used for the first cylinder 10 , the second cylinder 13 , and the third cylinder 15 .
  • the bogie 4 with a molding board has been carried in the station 17 for carrying a mold in.
  • the cope 2 and the drag 3 are carried in the direction of the arrow 6 from the flaskless molding machine 1 to be mounted on the bogie 4 with a molding board.
  • the cope 2 and the drag 3 that have been mounted on the bogie 4 with a molding board are intermittently conveyed by the means for conveying in the direction of the arrow 7 by a pitch to be sent to the station 18 for detecting a misalignment.
  • a misalignment between the cope 2 and the drag 3 is detected at the station 18 for detecting a misalignment.
  • detecting a misalignment between the cope 2 and the drag 3 is discussed in detail.
  • the means for clamping the bogie with a molding board which means is not shown, clamps the bogie 4 with a molding board that is positioned at the station 18 for detecting a misalignment to fix the position of the bogie 4 with a molding board.
  • the frame 14 for moving up and down is moved up or down so that the position in the Z-direction is adjusted.
  • the respective means for measuring distances to the cope and the drag are located so that the midpoint between the projecting centers of the first means 8 for measuring and the first means 9 for measuring is at, the same height as the midpoint between the projecting centers of the second means 11 for measuring and the second means 12 for measuring.
  • the frame 14 for moving up and down is moved up or down so that the midpoints between the projecting centers are at the same height as the height of the parting plane 19 between the cope 2 and the drag 3 .
  • the height from the upper surface of the bogie 4 with a molding board to the parting plane 19 is the same as the height of the drag 3 .
  • the height of the drag 3 is measured for every mold by a means for measuring, e.g., an encoder, of the flaskless molding machine 1 , which means is not shown.
  • the height of the parting plane 19 can be known for every mold.
  • the first means 8 for measuring and the first means 9 for measuring are moved back and forth in the Y-direction.
  • the stroke L 1 of the movement (see FIG. 7 ) is set to be 300 mm, which is about a half of the length of the cope 2 and the drag 3 .
  • the distances in the X-direction to the sides of the cope 2 and the drag 3 are measured.
  • the distance Si from the tip of the first means 8 for measuring to the first side 2 a of the cope is measured by the first means 8 for measuring.
  • the distance S 2 from the tip of the first means 9 for measuring to the first side 3 a of the drag is measured by the first means 9 for measuring.
  • the distances to at least parts of the sides of the cope and the drag are continually measured at predetermined intervals along the sides of the cope and the drag.
  • the distances are measured at every 1 mm interval along the sides. Incidentally, while moving backward in that movement the distances S 1 , S 2 are not measured.
  • the first means 8 for measuring and the first means 9 for measuring are moved back to the original positions.
  • the second means 11 for measuring and the second means 12 for measuring are moved back and forth in the X-direction.
  • the stroke L 2 of the movement (see FIG. 7 ) is set to be 200 mm, which is less than the length of the cope 2 and the drag 3 .
  • the distance S 3 from the tip of the second means 11 for measuring to the second side 2 b of the cope is measured by the second means 11 for measuring.
  • the distance S 4 from the tip of the second means 12 for measuring to the second side 3 b of the drag is measured by the second means 12 for measuring.
  • the distances to at least parts of the sides of the cope and the drag are continually measured at predetermined intervals along the sides of the cope and the drag.
  • the distances are measured at every 1 mm interval along the sides. Incidentally while moving backward in the reciprocating movement the distances S 3 , S 4 are not measured.
  • the second means 11 for measuring and the second means 12 for measuring are moved back to the original positions.
  • the clamp is released by the means for clamping the bogie with a molding board from the bogie 4 with a molding board that is positioned at the station 18 for detecting a misalignment.
  • the cope 2 and the drag 3 and the bogie 4 with a molding board which are positioned at the station 18 for detecting a misalignment, are intermittently conveyed by the means for conveying in the direction of the arrow 7 by a pitch to be sent out from the station 18 for detecting a misalignment.
  • a jacket (not shown) is capped in a following process and a weight (not shown) is mounted on the upper surface of the cope 2 . Thereafter molten metal is poured into the cope 2 and the drag 3 .
  • the difference S 5 between the distance S 1 and the distance S 2 is obtained to be compared with a predetermined range (an allowable range).
  • the predetermined range is determined by adding the allowable range to a reference value, which is a dimension determined by the design. As an example in this embodiment, the reference value is 7 mm and the allowable range is ⁇ 0.5 mm. Thus the predetermined range is 6.5-7.5 mm. If the difference S 5 is outside of this range, then a misalignment is determined to have occurred. Also, the difference S 6 between the distance S 3 and the distance S 4 is obtained.
  • the difference S 6 is outside of the predetermined range, then a misalignment is determined to have occurred.
  • the reference value is 2 mm and the allowable range is ⁇ 0.5 mum.
  • the predetermined range is 1.5-2.5 mm. If the difference S 6 is outside of this range, then a misalignment is determined to have occurred.
  • these operations for calculating, comparing, determining, etc. are automatically carried out by the means for calculating a degree of a misalignment between the cope and the drag, a controller, etc., which are not shown.
  • the distances S 1 , S 2 , S 3 , S 4 are measured at every 1 mm interval along the sides of the cope and the drag.
  • the differences S 5 , S 6 are obtained multiple times.
  • the difference that is used for determining a misalignment can be arbitrarily selected from the differences S 5 , S 6 that are continually obtained multiple times. For example, if one of the differences S 5 , S 6 is outside of the predetermined range, then a misalignment is determined to have occurred. For another example, if both differences S 5 , S 6 that are continually obtained multiple times are outside of the predetermined range, then a misalignment is determined to have occurred.
  • a misalignment is determined to have occurred by using differences at multiple points along the sides 2 a, 2 b, 3 a, 3 b of the cope 2 and the drag 3 , a misalignment can be reliably determined to have occurred.
  • An instruction is sent by a controller to the pouring machine, which is not shown, so that no molten metal will be poured into the cope 2 and the drag 3 that have been determined to have a misalignment as discussed above.
  • the first means 8 for measuring and the first means 9 for measuring are movable by the first cylinder 10 , i.e., an actuator, in the direction for conveying the cope 2 and the drag 3 .
  • the second means 11 for measuring and the second means 12 for measuring are movable in the direction that is perpendicular to the direction for conveying the cope 2 and the drag 3 .
  • the first means 8 for measuring, the first means 9 for measuring, the second means 11 for measuring, and the second means 12 for measuring can be simultaneously moved up and down by the third cylinder 15 , i.e., an actuator.
  • the positions in the Z-direction can be advantageously adjusted within a short period of time.
  • the laser-type displacement sensors are used for the first means 8 for measuring, the first means 9 for measuring, the second means 11 for measuring, and the second means 12 for measuring.
  • the distances to the sides of the cope and drag can be correctly measured.
  • the device can be made to be compact.
  • the present invention if the difference S 5 between the distance S 1 to the first side 2 a of the cope as measured by the first means 8 for measuring and the distance S 2 to the first side 3 a of the drag as measured by the first means 9 for measuring or the difference S 6 between the distance S 3 to the second side 2 b of the cope as measured by the second means 11 for measuring and the distance S 4 to the second side 3 b of the drag as measured by the second means 12 for measuring is outside of the predetermined allowable range, then a misalignment is determined to have occurred.
  • a misalignment in the assembled cope 2 and drag 3 that have been molded by the flaskless molding machine 1 which misalignent is not visible, can be advantageously detected.
  • the distances are continually measured at predetermined intervals along at least parts of the sides of the cope and the drag by the first means 8 for measuring, the first means 9 for measuring, the second means 11 for measuring, and the second means 12 for measuring.
  • the second means 11 for measuring and the second means 12 for measuring are moved back and forth in the X-direction, by means of the second cylinder 13 .
  • the order of the movements is not limited to the above. They may be moved in the reverse order or at the same time.
  • the distances S 1 , S 2 , S 3 , S 4 are continually measured at the predetermined intervals along at least parts of the sides of the cope and the drag.
  • the measurements are not limited to the above.
  • the distances may be continually measured at the predetermined intervals along the entire sides of the cope and the drag.
  • a misalignment is determined to have occurred.
  • the determination is not limited to the above. Only if both of the differences S 5 , S 6 are outside of the predetermined allowable range may a misalignment be determined to have occurred.
  • the device 5 is located downstream of the station 17 for carrying a mold in by a pitch.
  • the location of it is not limited to the above.
  • the device 5 may be located anywhere, including at the station 17 for carrying a mold in, but upstream of the position where molten metal is poured into the cope 2 and the drag 3 .
  • the actuators are not limited to the first cylinder 10 , the second cylinder 13 , or the third cylinder 15 . They may be another type. For example, they may be motors.
  • data on the location of the center of, the angle of rotation of, and the degree of misalignment of, the cope 2 and the drag 3 are sent from the device 5 , 40 , 60 to the dedicated means 48 for calculating or to a controller for another device, to be processed.
  • the data may be sent to a personal computer, a main frame (a general-purpose computer), a server, a cloud server, etc., that are positioned outside the foundry, through the internet, to be processed.
  • the data that have been processed by such a computer such as the data for operating the device, may be sent back to the device in the foundry, including the device 5 , 40 , 60 , through the internet.
  • the connection with the internet may be made through a controller for another device, not directly through the device 5 , 40 , 60 .

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Casting Devices For Molds (AREA)
  • Length Measuring Devices With Unspecified Measuring Means (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Continuous Casting (AREA)
US15/777,313 2016-01-12 2016-12-21 Device and method that can detect misalignment between cope and drag Abandoned US20180326475A1 (en)

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JP2016-003646 2016-01-12
JP2016003646 2016-01-12
PCT/JP2016/088068 WO2017122510A1 (fr) 2016-01-12 2016-12-21 Dispositif de détection de déplacement de moule et procédé de détection de déplacement de moule pour des moules supérieur et inférieur

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JP (1) JP6589997B2 (fr)
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US11364537B2 (en) * 2017-10-19 2022-06-21 Sintokogio, Ltd. Method and flaskless molding line for reducing mold shift of cope and drag that have been molded by flaskless molding machine and assembled

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WO2018168055A1 (fr) * 2017-03-13 2018-09-20 新東工業株式会社 Procédé et dispositif de fonctionnement d'un équipement de moulage
JP6874709B2 (ja) * 2018-02-13 2021-05-19 新東工業株式会社 上下鋳型の型ずれ検知装置、及び、上下鋳型の型ずれ検知方法
JP6863313B2 (ja) 2018-02-23 2021-04-21 新東工業株式会社 キャビティ部のずれによる不良を防止する方法
JP7314871B2 (ja) * 2020-07-09 2023-07-26 新東工業株式会社 強度計測装置及び強度計測方法

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KR20180103832A (ko) 2018-09-19
JP6589997B2 (ja) 2019-10-16
MX2018006484A (es) 2018-08-15
JPWO2017122510A1 (ja) 2018-11-01
CN108348987A (zh) 2018-07-31
BR112018011114A2 (pt) 2018-11-21
EP3403742A1 (fr) 2018-11-21
EP3403742A4 (fr) 2019-08-07
CN108348987B (zh) 2020-06-23

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