Classifications

• • 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
  • B22C15/00—Moulding machines characterised by the compacting mechanism; Accessories therefor
  • B22C15/02—Compacting by pressing devices only
  • B22C15/08—Compacting by pressing devices only involving pneumatic or hydraulic mechanisms
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22C—FOUNDRY MOULDING
  • B22C15/00—Moulding machines characterised by the compacting mechanism; Accessories therefor
  • B22C15/28—Compacting by different means acting simultaneously or successively, e.g. preliminary blowing and finally pressing

Definitions

• the present invention relates to a molding method and system with a molding apparatus. More particularly, it relates to a molding method and system with a molding apparatus by which the density of a mold is made uniform, by which little molding sand overflows the molding apparatus, and by which the amount of any molding sand that must be removed from the mold is less compared to the prior art.
• the molding sand is suppHed by supplying compressed air.
• the molding sand is suppHed through a plurahty of nozzles.
• any one of the capacity of the molding sand filling cavity, the positions and strength of the aeration, and the strength of the pressurized air flow or the pressurized air surge is controUed.
• the past molding data is stored in a storage device of a oontroUer of the molding apparatus with molding frames. Before the relevant operations are performed during the molding operation by the molding apparatus with molding frames, optimized values on the capacity of the molding sand filling cavity, the positions and strength of the aeration, and the strength of the pressurized air flow or the pressurized air surge are set.
• the covering apparatus has a plurahty of squeezing feet. They can pass through the plate of the covering apparatus and move up and down so that they jointly form an upper surface of the molding sand filling cavity. Any molding sand that is partially too much or too Httle is sensed when the density of a part of the mold is high or low. Too much or too Httle molding sand is sensed when the density of aH the molding sand is measured to be too high or too low.
• the past molding data includes not only the molding data for the immediately prior molding, but also some molding data previous to it.
• the immediately prior molding data as weU as the data that is taken based on some of the previous data, is used.
• the previous molding data is stored as a database, so that based on that data the capacity of the molding sand filling cavity etc. can be controUed by conventional methods such as a method of least squares and a fuzzy control method.
• the past molding data is connected through a communication line such as the Internet and radio communications to a computer that stores molding data for another molding apparatus through the controUer of the molding apparatus with molding frames.
• Fig. 7 is a cross sectional and plan view showing the main part of an apparatus of the second embodiment of this invention.
• Fig. 8 is a cross sectional and plan view showing the main part of the molding sand filling cavity of the third embodiment of this invention where the molding sand has not yet been suppHed to it.
• the squeezing feet are inserted into the space defined by the filling frame, so that they are arranged opposite respective portions of the casting pattern on the pattern plate. Also, the feet can temporarily be stopped so that certain distances are held between the squeezing feet and the corresponding portions of the casting pattern.
• Fig. 2 is a cross sectional and front view of a main part of a molding apparatus that includes a mechanism to supply molding sand to molding frames and a squeezing apparatus.
• a pattern plate 2 is disposed on a moving table 1, which is intermittently and horizontaUy moved by means of a conventional mechanism (not shown).
• a molding frame 3 is horizontaUy and vertically transported over the pattern plate 2 by a frame transporting apparatus (not shown), so that the frame 3 can be put on the pattern plate 2 when the moving table 1 temporarily stops at a certain position.
• a covering apparatus 5 is disposed above the molding frame 3 that is stopped at a certain position.
• the covering apparatus 5 has a plurahty of squeezing feet and a filling frame 4.
• the frame 4 is hung from the covering apparatus 5.
• the frame 4 can move up and down over a certain distance from the lower end of the covering apparatus 5.
• the covering apparatus can be moved up and down by means of an actuator (not shown).
• the plurahty of the squeezing feet 8 are positioned along the center of the covering apparatus 5 and perform the squeezing operation.
• the covering apparatus 5 has a holding member 6, which is shaped like an inverted box, from which the filling frame 4 is hung.
• the filling frame 4 can move up and down over a certain distance along the holding member 6.
• a square tubular hopper 7 is located on the upper surface of the holding member 6 as a sand supplying apparatus.
• a microcomputer 18 is electricaUy connected to the pressure sensors 15 and the directional control valves 17.
• a safety valve or a rehef valve may be connected to each line between the first channel 12 and the flow-control valve 17.
• the microcomputer 18 operates as a distance calculating apparatus. Based on the results of the measurements of the sensors 15, it calculates the distances between the surfaces of patterns on the pattern plate and the lower ends of the squeeze feet, which ends oppose those surfaces, for the next squeezing operation in the sand filling cavity.
• the squeeze feet are held at certain positions so that the ratios of the distances between the surfaces of the patterns on the pattern plate and the lower ends of the squeeze feet before a squeezing operation is performed to those after a squeezing operation is finished can nearly equal each other. For example, if the distances between the surfaces of the patterns on the pattern plate and the lower ends of the squeeze feet before a squeezing operation is performed are A and B (as in Fig. 2), and if the distances after a squeezing operation is finished are a and b (as in Fig.
• Nozzles 16 are formed within each of the cavities that are surrounded by a plurahty of the squeezing feet 8 and are defined by the holding member 6. Each nozzle 16 is funneled. The outlet of each nozzle 16 is optional. It may be shaped to be circular, elHptical, rectangular, square, etc. Also, such shapes may be combined. The nozzle is not limited to have the shape of a funnel. It may have other shapes (as in Fig. 5).
• the step of defining the molding sand filling cavity aUows the molding sand filling cavity to be defined by means of the pattern plate 2, the molding frame 3, which is to be put on the pattern plate 2, the filling frame 4, which is to be put on the molding frame 3, and the covering apparatus 5, which has a plurahty of the squeezing feet 8, which squeezing feet can be inserted into the filling frame 4.
• the squeezing feet 8 can be temporarily held at certain positions so that the lower ends of the squeezing feet and the surfaces of the patterns on the pattern plate are opposed and so that certain distances can be kept between them.
• the molding frame 3 is put on the pattern plate 2
• the filling frame 4 is put on the molding frame 3
• the covering apparatus 5, which has the squeezing feet is put on the filling frame 4.
• some of the directional-control valves 14 are exchanged, so that pressurized oU is suppHed through the relevant first channels 12 to the spaces that are defined by the pistons 10 and the squeezing feet 8.
• the distances A and B are selected so that the ratios of them to those that wiU be determined may be substantiaUy close to each other. That is, the squeezing feet 8 that are positioned opposed to the patterns on the pattern plate that are relatively high are moved down so that the amount of molding sand that is to be compressed may be decreased compared to the prior art. In contrast, the squeezing feet 8 that are positioned opposed to the patterns on the pattern plate that are relatively low are moved down just a Httle so that the amount of molding sand that is to be compressed may increase. Thus, this aUows the molding sand filling cavity to be defined by the pattern plate 2, the molding frame 3, the filling frame 4, and the plurahty of the squeezing feet 8.
• molding sand is suppHed by molding sand supplying mechanism (not shown) to the sand hopper 7, which is positioned at the upper part of the covering apparatus 5, which has a plurahty of the squeezing feet 8, so that the molding sand is suppHed from the sand hopper 7 through a plurahty of the nozzles 16 to the molding sand filling cavity.
• the covering apparatus 5, which has a plurahty of the squeezing feet 8 is moved down by an actuator (not shown), so that the molding sand within the molding sand filling cavity is squeezed by the plurahty of the squeezing feet 8.
• a microcomputer 18 When the squeezing operation is completed, the reaction forces of the molding sand to the squeezing feet 8 (that is, the density of the mold) are sensed by the pressure sensor 15. Based on this measurement, to adjust the positions of the squeezing feet 8 within the molding sand filling cavity a microcomputer 18 generates an order signal to suitably control flow-control valves 17 that were selected for the previous squeezing operation when the molding sand was suppHed to the molding sand filling cavity.
• the amount of molding sand that is suppHed to the molding sand filling cavity is increased or decreased, so that the density of the mold that is determined when the squeezing operation is performed becomes uniform or the reaction forces that are caused when the squeezing operation is performed become the same.
• oil pressure is used for a driving source to move the squeezing feet.
• Air pressure may also be used for the driving source.
• the squeezing feet may be electricaUy moved.
• the directional control valve is connected to an air driving source such as an air unit.
• air pressure both of the pressures in the spaces that are connected to the first and second channels 12, 13 are controUed, so that the respective positions of the squeezing feet 8 can be graduaUy adjusted at the upper, middle, and lower positions, etc.
• the position ofthe fiUing frame 6, to which the squeezing feet is connected is moved up and down, so that all the distances between the lower ends of the squeezing feet and the opposed surfaces of the patterns on the pattern plate can be synchronously adjusted.
• Fig. 6 shows a flowchart of a squeezing operation that is performed by the second embodiment.
• This flowchart differs from that for the first embodiment in that after a molding sand hopper is filled with molding sand, a pressurized air flow or a pressurized air surge acts on the molding sand, and then the molding sand is compressed by the squeezing feet.
• the second embodiment of this invention includes valves 20 that close the outlets of the nozzles to prevent air from flowing into the molding sand cavity when a pressurized air flow or a pressurized air surge acts, and includes an air supplying apparatus.
• Fig. 7 shows the half of the apparatus denoted by (a).
• Fig. 8 shows a schematic view of a molding apparatus of this embodiment.
• the molding apparatus includes a controUer 31 to which a storage device 32 is connected. It stores past molding data.
• Various sensors are electricaUy connected to the controUer 31, so that signals are transmitted from the sensors to the controUer 31 and then are stored in the storage device 32.
• Molding data such as on the density of the mold and the capacity of the molding sand filling cavity is taken by a pressure sensor etc. Such data is used to control the capacity of the molding sand filling cavity, the positions and strength of the aeration, and the strength of the pressurized air flow or the pressurized air surge.
• the past molding data can be sent through the controUer of the molding apparatus with frames to a computer of another molding apparatus (not shown) that is used to store molding data.
• a central computer, a data server-type computer, etc. may be used for such a computer.
• the results calculated by the computer are transmitted to a controUer of an operational molding apparatus, so that the capacity of the molding sand filling cavity, the positions and strength of the aeration, and the strength of the pressurized air flow or the pressurized air surge can be optimized.
• molding data can be commonly used between the computers, so that it ensures that a more precise control can be achieved.
• the molding system with molding frames having a pattern plate, a molding frame that can be put on the pattern plate, a filling frame that can be put on the molding frame, a covering apparatus having a plurahty of squeezing feet that can enter the filling frame and that can be temporarily held at certain positions where certain distances are kept between the lower ends of the squeezing feet and surfaces of patterns on the pattern plate, which surfaces are opposed to the lower ends, and a sand supplying apparatus for supplying molding sand to the molding sand filling cavity that is defined by the pattern plate, the molding frame, the filling frame, and the covering apparatus, which system is characterized by sensors for measuring the reaction forces to respective squeezing feet, a storage device that stores molding data based on the measurements of the sensors for measuring reaction forces, and a distance calculation device for calculating distances between the lower ends of the squeezing feet relating to the molding sand filling cavity and the patterns on the pattern plate that are opposed to the lower ends of the sque
• positions to which molding sand is suppHed can be selected. Also, an excess of and lack of the molding sand can be overcome.
• the molding system further including a closing member that closes the lower parts of the nozzles, and an air supplying apparatus for introducing air after the molding sand is suppHed, the molding sand can be prevented from reversely flowing to the molding sand supplying apparatus.
• molding data that is stored in a storage device of a controUer of a molding apparatus with molding frames can be used as past molding data
• molding data that is stored in a storage device of a controUer of the molding apparatus can be used as previous molding data, so that experiences can be effectively used when the molding apparatus is controUed.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Casting Devices For Molds (AREA)
• Injection Moulding Of Plastics Or The Like (AREA)
• Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
• Heating, Cooling, Or Curing Plastics Or The Like In General (AREA)

Priority Applications (4)

Applications Claiming Priority (2)

Publications (1)

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Citations (3)

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• 2000
  • 2000-01-14 JP JP2000005378A patent/JP3413798B2/ja not_active Expired - Fee Related
  • 2000-03-15 ID IDW00200101987A patent/ID30244A/id unknown
  • 2000-05-15 WO PCT/JP2000/003099 patent/WO2001051235A1/en not_active Ceased
  • 2000-05-15 EP EP00927769A patent/EP1163066B1/en not_active Expired - Lifetime
  • 2000-05-15 TR TR2001/02681T patent/TR200102681T1/xx unknown
  • 2000-05-15 AT AT00927769T patent/ATE300375T1/de not_active IP Right Cessation
  • 2000-05-15 DE DE60021538T patent/DE60021538T2/de not_active Expired - Lifetime
  • 2000-05-15 US US09/570,681 patent/US6470953B1/en not_active Expired - Lifetime
  • 2000-05-15 ES ES00927769T patent/ES2246851T3/es not_active Expired - Lifetime
  • 2000-05-15 BR BRPI0009015-8A patent/BR0009015A/pt not_active IP Right Cessation
  • 2000-05-15 CN CNB008067937A patent/CN1263566C/zh not_active Expired - Lifetime
  • 2000-05-15 KR KR1020017011608A patent/KR100623056B1/ko not_active Expired - Lifetime
  • 2000-08-25 TW TW089117172A patent/TW461832B/zh not_active IP Right Cessation

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