Flask mating misalignment detection method and detection device for molds with flasks
10799941 ยท 2020-10-13
Assignee
Inventors
Cpc classification
B22C19/04
PERFORMING OPERATIONS; TRANSPORTING
International classification
B22C19/04
PERFORMING OPERATIONS; TRANSPORTING
Abstract
[Problem] To provide a method and device that automatically detects misalignment during flask mating in an automatic flask mating device for molding flasks for casting. [Solution] In an automatic flask mating device, an external force applied to a cope with a cope molding flask M1 during flask mating is detected by means of a physical quantity detection sensor 60, quantified by a computation/storage/determination processing device 61, and then compared with a numerical value at a normal time for determination to thereby determine whether the flask mating has normally completed and detect flask mating misalignment. A force sensor is preferably used as the physical quantity detection sensor.
Claims
1. A flask mating misalignment detection method for molds with flasks comprising, when automatically flask mating a cope with a cope molding flask and a drag with a drag molding flask molded by a molding machine: detecting a force generated by a fitting together of pins and bushings provided on the cope molding flask and the drag molding flask by means of a physical quantity detection sensor capable of detecting the force; and determining whether the flask mating has normally completed without misalignment on the basis of a fitting force computed from an output of the physical quantity detection sensor.
2. The flask mating misalignment detection method for molds with flasks according to claim 1, wherein the physical quantity detection sensor is capable of detecting the force in directions of at least two axes or more.
3. The flask mating misalignment detection method for molds with flasks according to claim 1, wherein a force sensor is used as the physical quantity detection sensor.
4. A flask mating misalignment detection method for molds with flasks comprising, when automatically flask mating a cope with a cope molding flask and a drag with a drag molding flask molded by a molding machine: detecting a combining force generated by combining of the cope and the drag by means of a physical quantity detection sensor capable of detecting the force; and determining whether the flask mating has normally completed without misalignment on the basis of the combining force detected by the physical quantity detection sensor.
5. The flask mating misalignment detection method for molds with flasks according to claim 4, wherein the physical quantity detection sensor is capable of detecting the force in directions of at least two axes or more.
6. The flask mating misalignment detection method for molds with flasks according to claim 4, wherein a force sensor is used as the physical quantity detection sensor.
7. A flask mating misalignment detection device for molds with flasks incorporated into an automatic flask mating device that automatically flask-mates a cope with a cope molding flask and a drag with a drag molding flask molded by a molding machine, wherein: the cope with the cope molding flask and the drag with the drag molding flask comprise a positioning means comprising pins and bushings; and the flask mating misalignment detection device for molds with flasks comprises: a physical quantity detection sensor configured to detects a force generated when the cope with the cope molding flask is lowered toward the drag with the drag molding flask and the pins and bushings are fitted together; and a processor configured to function as: a computation unit configured to computes a fitting force on the basis of the force detected by the physical quantity detection sensor; and a determination unit configured to determine whether the flask mating has normally completed on the basis of the fitting force, which is a computation result of the computation unit.
8. The flask mating misalignment detection device for molds with flasks according to claim 7, wherein the physical quantity detection sensor is capable of detecting the force in directions of at least two axes or more.
9. The flask mating misalignment detection device for molds with flasks according to claim 7, wherein the physical quantity detection sensor is a force sensor.
10. A flask mating misalignment detection device for molds with flasks incorporated into an automatic flask mating device that automatically flask-mates a cope with a cope molding flask and a drag with a drag molding flask molded by a molding machine, wherein the flask mating misalignment detection device for molds with flasks comprises: a physical quantity detection sensor that detects a force generated when the cope with the cope molding flask is lowered toward the drag with the drag molding flask and flask mating is performed; and a processor configured to function as: a computation unit configured to compute a fitting force on the basis of the force detected by the physical quantity detection sensor; and a determination unit configured to determine whether the flask mating has normally completed on the basis of the fitting force, which is a computation result of the computation unit.
11. The flask mating misalignment detection device for molds with flasks according to claim 10, wherein the physical quantity detection sensor is capable of detecting the force in directions of at least two axes or more.
12. The flask mating misalignment detection device for molds with flasks according to claim 10, wherein the physical quantity detection sensor is a force sensor.
Description
BRIEF DESCRIPTION OF DRAWINGS
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DESCRIPTION OF EMBODIMENTS
(10) An embodiment of the present invention is described below with reference to the drawings. As shown in
(11) In addition, an inverting machine (not shown) that inverts the cope with a cope flask M1 is installed on the first conveying line 4. After the cope with a cope flask M1 is vertically inverted by the inverting machine and the cope with a cope flask M1 and the drag with a drag flask M2 are flask-mated, the flask-mated cope and drag with flasks M are sent out to a second conveying line 7 (
(12) A cope flask protrusion Ff is formed on both opposite ends of the cope flask (cope molding flask) F1 of the cope with a cope flask M1. In addition, both the upper and lower surfaces of the cope flask protrusion Ff are processed because of the rolling of rollers 2a of the roller conveyor 2 that convey the cope with a cope flask M1. Among a cope flask protrusion upper surface processed surface Ffa and a cope flask protrusion lower surface processed surface Ffb processed on both the upper and lower surfaces, conveying rollers 49 to be described later in more detail can be attached to and removed from the cope flask protrusion lower surface processed surface Ffb by means of an also later-described lifting action of a first lifting cylinder 31 and an opening and closing action of an opening and closing cylinder 46.
(13) The automatic flask mating device according to the present embodiment comprises: a first lifting cylinder 31; and a lifting portion 34, comprising a lifting table 32 fixed to a tip of a rod 31a of the first lifting cylinder 31 and a support mechanism 33 provided on the lifting table 32.
(14) The first lifting cylinder 31 is provided with an encoder (not shown) as a detector to be able to detect displacement positions of the rod 31a, and among four-sided frames 38a disposed over four support columns 37 erected on the floor surface and a central frame 38b, the cylinder is provided downward on the central frame 38b. In addition, a guide rod 39 is provided on both sides of the first lifting cylinder 31. To measure displacement of the rod 31a, a linear scale (not shown) may for example be used as a detector instead of the encoder. In addition, a hydraulic cylinder, an air cylinder, or an electric cylinder may be used as the first lifting cylinder 31.
(15) As shown in
(16) In addition, in the present embodiment, among the pair of roller frames 48, a cope flask clamp 50 that performs positioning of the cope with a cope flask M1 is mounted to one of the roller frames 48 via a mounting member 63 and a physical quantity detection sensor 60 to be described next using
(17) As shown in
(18) The physical quantity detection sensor 60 is capable of detecting a force acting on the cope flask clamp 50 in directions of at least two axes or more. In the present embodiment, the physical quantity detection sensor 60 detects a force in two directions in a horizontal plane. For example, the physical quantity detection sensor 60 detects a force in two axial directions, as in: direction X, the direction in which a side of the cope with a cope flask M1 provided opposite to the roller frames 48 extends; and direction Y, the direction orthogonal to direction X in a horizontal plane and in which the rod of the clamp cylinder extends.
(19) The physical quantity detection sensor 60 is connected to a computation/storage/determination processing device 61 via signal wiring 62. The computation/storage/determination processing device 61 has a function of computing a signal output from the physical quantity detection sensor 60 to derive a value, which is then compared with a previously stored value for determination.
(20) In addition, a drag flask clamp (not shown) for the positioning of the drag with a drag flask M2 relative to the positioning of the cope with a cope flask M1 is mounted to a support column 37.
(21) In the automatic flask mating device 1 configured as described above, first, as shown in
(22) Next, as shown in
(23) In this state, as shown in
(24) Here, when the first lifting cylinder 31 is extended and the cope flask F1 is lowered onto the conveyed drag flask F2, positioning pins F1g provided on the cope flask F1 and positioning bushings F2g provided on the drag flask F2 fit together, thereby allowing the cope with a cope flask M1 and the drag with a drag flask M2 to be flask-mated without any positioning misalignments. In a casting line, because operation is performed such that the combining of the cope flask F1 and the drag flask F2 is continually the same, the external force that occurs on the cope flask F1 when the positioning pins F1g provided on the cope flask F1 and the positioning bushings F2g provided on the drag flask F2 fit together during flask mating is constant in an ideal state.
(25) When equipment is in a nearly ideal state, for example when a new line is established or line maintenance has completed, the external force that occurs on the cope flask F1 when the positioning pins F1g provided on the cope flask F1 and the positioning bushings F2g provided on the drag flask F2 fit together is detected by means of the physical quantity detection sensor 60 and stored in the computation/storage/determination processing device 61 beforehand. A computation means 64 that computes a fitting force, the force generated by the fitting together of the pins F1g and bushings F2g of the cope flask F1 and the drag flask F2, from the external force measured by the physical quantity detection sensor 60; and a determination means 65, which determines whether flask mating has normally completed on the basis of the computation result of the computation means 64, are incorporated into the computation/storage/determination processing device 61. In the case of a general casting line, operation is performed such that the cope flask F1 and the drag flask F2 are continually the same combination. Thus, a numerical value during flask mating for each combination is stored.
(26) However, in practice, the positioning pins F1g and the positioning bushings F2g become worn as operation continues, causing rattling in the fitting together of the positioning pins F1g and the positioning bushings F2g and in turn degrading flask mating accuracy. Then, as the external force that occurs on the cope flask F1 when the positioning pins F1g provided on the cope flask F1 and the positioning bushings F2g provided on the drag flask F2 fit together in flask mating, differing external forces that have deviated from the ideal state occur.
(27) In each flask mating that is performed, the external force that occurs on the cope flask F1 when the positioning pins F1g provided on the cope flask F1 and the positioning bushings F2g provided on the drag flask F2 fit together is detected by means of the physical quantity detection sensor 60, and in the computation/storage/determination processing device 61, the detection signal is quantified by means of computation and compared with a previously stored numerical value of an ideal state.
(28) Here, for example, the value measured by the physical quantity detection sensor 60 is compared for each axis.
(29) At this time, if the comparison value of the external force detected for each axis in the physical quantity detection sensor 60 is deviating by 200 N (about 20 Kgf) or more even in one axis, or, if the comparison value of the external force detected for each axis moment in the physical quantity detection sensor 60 is deviating by 200 N.Math.m (about 20 kgf.Math.m) or more even in one axial moment, this is determined to be an abnormal state in which misalignment has occurred in flask mating.
(30)
(31) In the flask mating misalignment detection method for molds with flasks, once the process is initiated (step S1), when automatically flask mating a cope with a cope flask M1 and a drag with a drag flask M2, a physical quantity detection sensor 60 detects an external force generated by the fitting together of pins F1g and bushings F2g provided on a cope flask F1 and a drag flask F2 (step S3).
(32) The computation means 64 receives the detection result detected by the physical quantity detection sensor 60 and computes a fitting force (step S5).
(33) A determination means 65 determines whether flask mating has normally completed on the basis of the fitting force, which is the computation result of the computation means 64 (step S7), and the process ends (step S9).
(34) Next, the effects of the flask mating misalignment detection method and detection device for molds with flasks will be described.
(35) The flask mating misalignment detection method for molds with flasks in the present embodiment, when automatically flask mating a cope with a cope molding flask M1 and a drag with a drag molding flask M2 molded by a molding machine, detects a force generated by the fitting together of pins F1g and bushings F2g provided on a cope molding flask F1 and a drag molding flask F2 by means of a physical quantity detection sensor 60 capable of detecting the force, and determines whether the flask mating has normally completed without misalignment on the basis of a fitting force computed from an output of the physical quantity detection sensor 60.
(36) In addition, the flask mating misalignment detection device for molds with flasks in the present embodiment is incorporated into an automatic flask mating device 1 that automatically flask-mates a cope with a cope molding flask M1 and a drag with a drag molding flask M2 molded by a molding machine, wherein the cope with a cope molding flask M1 and the drag with a drag molding flask M2 comprise a positioning means F1g and F2g comprising pins F1g and bushings F2g, and the flask mating misalignment detection device for molds with flasks comprises: a physical quantity detection sensor 60 that detects a force generated when the cope with a cope molding flask M1 is lowered toward the drag with a drag molding flask M2 and the pins F1g and the bushings F2g are fitted together; a computation means 64 that computes a fitting force on the basis of the force measured by means of the physical quantity detection sensor 60; and a determination means 65 that determines whether the flask mating has normally completed without misalignment on the basis of the computation result of the computation means 64.
(37) According to such a configuration and method, it is possible to automatically detect flask mating abnormalities that occur due to wearing of the positioning pins F1g and the positioning bushings F2g, in turn allowing countermeasures to be taken, such as not pouring molten metal into cope and drag with flasks M in which there was flask mating misalignment, and the occurrence rate of casting defects can be reduced. Furthermore, because the wearing of the positioning pins F1g and the positioning bushings F2g can be automatically detected, predictive maintenance becomes possible. For example, the time of replacement of the positioning pins F1g and the positioning bushings F2g can be predicted in advance.
(38) (Modified Example of Embodiment)
(39) Next, a modified example of the embodiment above will be described. In the present modified example, the physical quantity detection sensor 60 detects a combining force generated by the combining of a cope and a drag.
(40) As indicated above, when the first lifting cylinder 31 is extended and the cope flask F1 is lowered onto the conveyed drag flask F2, the external force that occurs on the cope flask F1 due to flask mating is constant in an ideal state if molds, such as an island portion Mi of the cope with a cope flask M1 and an island portion Mi of the drag with a drag flask M2, complete flask mating without interference.
(41) When equipment is in a nearly ideal state, for example when a new line is established or line maintenance has completed, the external force that occurs on the cope flask F1 due to flask mating, when molds such as the island portion Mi of the cope with a cope flask M1 and the island portion Mi of the drag with a drag flask M2 complete flask mating without any interference in flask mating, is detected by means of the physical quantity detection sensor 60 and stored in the computation/storage/determination processing device 61 beforehand. At this time in the case of a general casting line, operation is performed such that the cope flask F1 and the drag flask F2 are continually the same combination. Thus, a numerical value during flask mating for each combination is stored.
(42) However, molding problems and the like can occur as operation continues. There can be interference between molds such as the island portion Mi of the cope with a cope flask M1 and the island portion Mi of the drag with a drag flask M2 in flask mating. This means, as the external force that occurs on the cope flask F1, differing external forces that have deviated from the ideal state occur.
(43) In each flask mating that is performed, the external force that occurs on the cope flask F1 during flask mating is detected by means of the physical quantity detection sensor 60, and in the computation/storage/determination processing device 61, the detection signal is quantified by means of computation to obtain a combining force, which is compared with a previously stored numerical value of the ideal state.
(44) Here, for example, the value measured by the physical quantity detection sensor 60 is compared for each axis.
(45) At this time, if the comparison value of the external force detected for each axis in the physical quantity detection sensor 60 is deviating by 50 N (about 5 kgf) or more even in one axis, or, if the comparison value of the external force detected for each axis moment in the physical quantity detection sensor 60 is deviating by at least 50 N.Math.m (about 5 kgf.Math.m) even in one axial moment, this is determined to be an abnormal state in which misalignment has occurred in flask mating.
(46) The flask mating misalignment detection method for molds with flasks in the present modified example is implemented in a manner similar to the embodiment described using
(47) In other words, once the process is initiated (step S1), when automatically flask mating a cope with a cope flask M1 and a drag with a drag flask M2, a physical quantity detection sensor 60 detects an external force generated by the combining of a cope flask F1 and a drag flask F2 (step S3).
(48) A computation means 64 receives the detection result detected by the physical quantity detection sensor 60 and computes a combining force (step S5).
(49) A determination means 65 determines whether flask mating has normally completed on the basis of the combining force, which is the computation result of the computation means 64 (step S7), and the process ends (step S9).
(50) The flask mating misalignment detection method for molds with flasks in the present modified example, when automatically flask mating a cope with a cope molding flask M1 and a drag with a drag molding flask M2 molded by a molding machine, detects a force generated by the combining of a cope F1 and a drag F2 by means of a physical quantity detection sensor 60 capable of detecting the force, and determines whether the flask mating has normally completed without misalignment on the basis of a combining force detected by means of the physical quantity detection sensor 60.
(51) In addition, the flask mating misalignment detection device for molds with flasks in the present modified example is incorporated into an automatic flask mating device 1 that automatically flask-mates a cope with a cope molding flask M1 and a drag with a drag molding flask M2 molded by a molding machine, wherein the flask mating misalignment detection device for molds with flasks comprises: a physical quantity detection sensor 60 that detects a force generated when the cope with a cope molding flask M1 is lowered toward the drag with a drag molding flask M2 and flask mating is performed; a computation means 64 that computes a combining force on the basis of the force measured by the physical quantity detection sensor 60; and a determination means 65 that determines whether the flask mating has normally completed on the basis of the computation result of the computation means 64.
(52) According to such a configuration and method, it is possible to automatically detect flask mating abnormalities that occur due to interference between the cope with a cope flask M1 and the drag with a drag flask M2, in turn allowing countermeasures to be taken, such as not pouring molten metal into cope and drag with flasks M for which abnormalities were detected, and the occurrence rate of casting defects can be reduced. Furthermore, because interference between the cope with a cope flask M1 and the drag with a drag flask M2 due to molding abnormalities can be automatically detected, the frequency of abnormalities can be automatically made clear and predictive maintenance becomes possible. For example, the time of maintenance for the molding machine can be predicted in advance.
Other Modified Examples
(53) The installation position of the physical quantity detection sensor 60 can be changed. For example, as shown in
(54) In addition, in the embodiment described above, the physical quantity detection sensor 60 detects a force in two axial directions, as in: direction X, the direction in which a side of the cope with a cope flask M1 provided opposite to the roller frame 48 extends; and direction Y, the direction orthogonal to direction X in a horizontal plane and in which the rod of the clamp cylinder extends, but is not limited thereto. For example, a force in two axial directions, as in the above-described direction X and direction Z orthogonal to both direction X and direction Y, may be detected, and a force in two axial directions, as in direction Y and direction Z, may be detected. A force in three axial directions, as in directions X, Y, and Z, may also be detected. The axial direction is not limited to the above-described directions X, Y, and Z, and may be other directions. In addition, force detection can also include moment detection. In other words, the physical quantity detection sensor 60 may for example be configured so as to be able to detect at least two values from among a total of six types of values as in the force in each of the axial directions X, Y, and Z and the moment about each of these axial directions.
REFERENCE SIGNS LIST
(55) F1 Cope flask (cope molding flask)
(56) Ff Cope protrusion
(57) Ffa Cope protrusion upper surface processed surface
(58) Ffb Cope protrusion lower surface processed surface
(59) F1g Positioning pin (positioning means)
(60) F2 Drag (drag molding flask)
(61) F2g Positioning bushing (positioning means)
(62) M Cope and drag with flasks
(63) M1 Cope with a cope flask (cope with a cope molding flask)
(64) M2 Drag with a drag flask (drag with a drag molding flask)
(65) Mi Island portion
(66) 1 Automatic flask mating device
(67) 2 Roller conveyor
(68) 2a Roller
(69) 3 Cushion cylinder
(70) 4 First conveying line
(71) 5 First conveying line molding board carriage
(72) 6 Fixed rail
(73) 7 Second conveying line
(74) 8 Second conveying line molding board carriage
(75) 9 Molding board carriage upper rail
(76) 31 First lifting cylinder
(77) 31a Rod
(78) 32 Lifting table
(79) 33 Support mechanism
(80) 34 Lifting portion
(81) 37 Support column
(82) 38a Frame
(83) 38b Central frame
(84) 39 Guide rod
(85) 41 Support member
(86) 42 Horizontal member
(87) 43 Guide pin
(88) 43a Stopper nut
(89) 44 Holder
(90) 45 Moving member
(91) 46 Opening and closing cylinder
(92) 47 Arm
(93) 48 Roller frame
(94) 49 Conveying roller
(95) 50 Cope flask clamp
(96) 60 Physical quantity detection sensor
(97) 61 Computation/storage/determination processing device
(98) 62 Signal wiring
(99) 63 Mounting member
(100) 64 Computation means
(101) 65 Determination means