Method and device for producing a casting mold for sand casting

Abstract

Methods and devices for producing a casting mold for sand casting are disclosed. In one embodiment, a method for producing a compacted mold for casting molten material may include positioning a model or pattern in a flask; filling the flask with compactable sand; and compacting the compactable sand around the model or pattern so as to form a compacted mold or compacted mold component suitable for casting. The compacting of the molding sand takes place in zones or regions smaller than a lateral extension of the flask based on a contour or a dimension of the model or pattern.

Claims

1. A method for producing a compacted mold for casting molten material, comprising: positioning a model or pattern in a flask; filling the flask with compactable sand; and compacting the compactable sand around the model or pattern so as to form a compacted mold or compacted mold component suitable for casting, wherein the compacting of the molding sand takes place in zones or regions smaller than a lateral extension of the flask based on a contour or a dimension of the model or pattern, and wherein the compacting comprises a plurality of successive compression strokes.

2. The method of claim 1, wherein the compacting is performed by a compacting unit comprising a plurality of compacting cylinders.

3. The method of claim 2, wherein at least a majority of the compacting cylinders have an identical diameter.

4. The method of claim 1, wherein compactable sand is refilled following a compression stroke.

5. The method of claim 2, wherein a computer program controls a pressing force and a stroke of the compacting cylinders.

6. A method for producing a compacted mold for casting molten material, comprising: positioning a model or pattern in a flask; filling the flask with compactable sand; and compacting the compactable sand around the model or pattern so as to form a compacted mold or compacted mold component suitable for casting, wherein the compacting of the molding sand takes place in zones or regions smaller than a lateral extension of the flask based on a contour or a dimension of the model or pattern, wherein the step of filling the flask and the step of compacting the compactable sand comprises a plurality of steps.

7. A method for producing a compacted mold for casting molten material, comprising: positioning a model or pattern in a flask; filling the flask with compactable sand; and compacting the compactable sand around the model or pattern so as to form a compacted mold or compacted mold component suitable for casting, wherein the compacting of the molding sand takes place in zones or regions smaller than a lateral extension of the flask based on a contour or a dimension of the model or pattern, wherein the compacting cylinders are positioned above the flask via one of a portal, a bridge and a robot, and one of these undergoes a change in position near the flask.

8. A method for producing a compacted mold for casting molten material, comprising: positioning a model or pattern in a flask; filling the flask with compactable sand; and compacting the compactable sand around the model or pattern so as to form a compacted mold or compacted mold component suitable for casting, wherein the compacting of the molding sand takes place in zones or regions smaller than a lateral extension of the flask based on a contour or a dimension of the model or pattern, wherein a head providing the compacting is laterally smaller that the flask and provides a horizontal movement with multiple compacting by displacing the head.

9. A method for producing a compacted mold for casting molten material, comprising: positioning a model or pattern in a flask; filling the flask with compactable sand; and compacting the compactable sand around the model or pattern so as to form a compacted mold or compacted mold component suitable for casting, wherein the compacting of the molding sand takes place in zones or regions smaller than a lateral extension of the flask based on a contour or a dimension of the model or pattern, wherein the compactable sand is replenished at areas where the pattern or model has a small height and requires more sand volume.

10. A device for producing a compacted mold for casting a castable material, comprising: a flask; a model that is positioned in a flask; wherein: the flask is filled with sand; a compacting unit comprising a compacting head having a plurality of compacting cylinders compacts the sand around the model so as to form a compacted mold suitable for casting using a molten material; the compacting unit only partially compacts the sand around the model or pattern; and a part of the compacting is in a certain lateral zone of the flask based on a contour or a dimension of the model or pattern; wherein the compacting unit comprises a portal, a bridge, or a robot that is adapted to be positioned above the flask and to undergo a change of position, wherein a head thereof being movable in space; wherein the compacting head is movable in three dimensions, and is positionable above the flask in an arbitrary manner.

11. The device of claim 10, wherein the part of the compacting is smaller than a base area of the flask.

12. The device of claim 10, each of the compacting cylinders of the head is movable vertically independently of a position of a compacting head relative to the flask.

13. The device of claim 10, wherein the cylinders are arranged symmetrically in accordance with a matrix.

14. The device of claim 10, further comprising a hydraulic system associated with the portal.

15. The device of claim 10, wherein the part compacting is in the certain lateral zone and repeated to complete the lateral extension of the flask in other zones of the flask.

Description

INTRODUCTION OF THE DRAWINGS

(1) In connection with the explanation of the preferred embodiment of the invention with reference to the drawings, also generally preferred embodiments and further developments of the teaching will be explained. In the drawing.

(2) FIG. 1 shows, in a schematic view, the fundamental arrangement of a model in a molding flask, with molding sand being filled in around the model and compacted;

(3) FIG. 2 shows, in a schematic view, an embodiment of a device according to the present invention whose compacting unit is positionable above and along a molding flask;

(4) FIG. 3 shows, in a schematic top view, the device according to FIG. 2; and

(5) FIG. 4 shows, in a schematic front view, the device according to FIG. 2.

DETAILED DISCLOSURE

(6) FIG. 1 shows, in a highly schematized view, the fundamental arrangement of a model 1 in a molding flask 2. When the model 1 has been positioned, the molding flask 2 is successively filled with molding sand (green sand) 3, the molding sand 3 being compacted around the model 1 so as to form a stable mold suitable for casting.

(7) The arrows 4 indicate that the compacting of the molding sand 3 takes place in certain zones or regions, through cylinders that are not shown in FIG. 1, taking into account the contour and/or dimensions of the model 1. Insofar, it is taken into consideration whether the molding sand 3 extends, unhindered, from the molding flask base 5 upwards or whether the molding sand 3 extends from the surface of the model 1 upwards, viz. over a much shorter distance than from the molding flask base 5.

(8) FIG. 2 shows, in a schematic view, the fundamental structural design of an embodiment of a device according to the present invention used for producing a casting mold for sand casting, wherein the model 1 is positioned in a molding flask 2, in accordance with the representation shown in FIG. 1. For compacting the molding sand that is filled in, or is to be filled into the molding flask 2, a pneumatically operated compacting unit 6 is provided, which comprises a compacting head 7 with a plurality of compacting cylinders 8.

(9) From FIG. 2 it can be seen that the compacting unit 6 is associated with a portal 9, or rather carried by the latter. The portal 9 is horizontally movable along a guide unit 10, linearly along the molding flask 2.

(10) The entire compacting head 7, together with the compacting cylinders 8, is movable on the portal 9 in a direction transversely to the guide unit 10, viz. along a portal guide 11.

(11) In addition, the compacting head 7 is vertically movable on the portal 9, each of the compacting cylinders 8 being, when seen individually, displaceable and movable in the compacting direction.

(12) According to the above statements, it can clearly be seen that the size or longitudinal dimensions of the molding flask 2, and also its height, no longer play an important part. The compacting unit 6 with the compacting head 7 and the individual compacting cylinders 8 can now be moved across the molding flask 2 in an arbitrary manner, and, in so doing, the compacting cylinders 8 can be positioned for compacting the molding sand with due regard to the contour and the dimensions of the model.

(13) From FIG. 2 it can also be seen that the hydraulic system 12 is associated with the portal 9, i.e. it is supported by the portal 9. This allows a compact structural design.

(14) It is also imaginable that the guide unit 10, on which or in which the portal 9 is guided, is adjustable in width, so that different portals can be used or portals that are adjustable in width can be utilized.

(15) In addition, the guide unit 10 may, when seen individually, be vertically adjustable, so that an optimum adaptation to the height of a molding flask 2, which is to be positioned between the guide elements 13 of the guide unit 10, can be carried out.

(16) The drive for all the above-mentioned possibilities may be of a pneumatic and/or electrical nature. A hydraulic drive is imaginable as well.

(17) FIG. 3 shows the device according to FIG. 2 in a schematic top view, in which the molding flask 2 can again be discerned.

(18) The portal guide 11 is configured as a crossbar. The compacting head 7 comprises a plurality of compacting cylinders 8 arranged in a matrix-like manner, the compacting cylinders 8 serving to compact the molding sand 3 contained in the molding flask 2.

(19) FIG. 4 shows the device according to FIG. 2 in a schematic front view, in which the molding flask 2 can again be seen. The model 1 is positioned in the molding flask 2 and covered by molding sand 3 to be compacted. In addition, FIG. 4 shows a filling aid 14 in the sense of a head attached to the actual molding flask 2, the compacting cylinders 8 of the compacting head 7 or compacting unit 6 projecting into the head in the case of an alternating application of pressure.

(20) The arrows 15 indicate the vertical adjustability of the guide elements 13.

(21) As regards additional advantageous further developments of the device according to the present invention, the general part of the description as well as the claims enclosed are referred to in order to avoid repetitions.

(22) Finally, it should explicitly be pointed out that the above described embodiment of the device according to the present invention only serves to explain the teaching claimed, without limiting the teaching to this embodiment.