METHOD AND SYSTEM FOR DIE CASTING

Abstract

A method and system of casting. The system of casting including a mold, a water inlet, and an outlet valve. The mold including a mold fluid inlet and a mold fluid outlet. The water inlet being selectively fluidly coupled to the mold fluid inlet via a first valve. The mold fluid outlet being fluidly coupled to the outlet valve.

Claims

1. A method of casting, the method comprising: determining a presence of or a non-presence of a leak within a mold of a casting system, the mold having a mold fluid inlet and a mold fluid outlet, the method of determining the presence of or non-presence of the leak comprising: closing an outlet valve provided downstream of and fluidly coupled to the mold fluid outlet; after closing the outlet valve, opening a first valve to selectively fluidly couple a water inlet to the mold fluid inlet; determining if a switch provided downstream of the first valve and upstream of the mold is opened or closed; if the switch is closed, determining the presence of a leak within the mold; and if the switch is opened, determining the non-presence of a leak within the mold.

2. The method of claim 1, further comprising if the switch is closed: opening a second valve to selectively fluidly couple a gaseous fluid through a gas inlet to the mold fluid inlet; closing the outlet valve; supplying a gaseous fluid to the mold through the mold fluid inlet; and purging water within the casting system through the leak in the mold.

3. The method of claim 1, wherein the mold defines an interior housing a part, the method further comprising: spraying the part; and determining the presence of or non-presence of the leak in tandem with, directly before, or directly after spraying.

4. The method of claim 3, further comprising closing a mold if no leak is determined.

5. The method of claim 3, further comprising terminating a casting of the part if the switch is closed.

6. The method of claim 1, further comprising if the switch is closed, communicating a presence of the leak.

7. The method of claim 1, further comprising: prior to opening the first valve, opening a third valve provided downstream the switch; and after opening the first valve to fluidly couple the water inlet to the mold fluid inlet, closing the first valve.

8. The method of claim 1, further comprising after closing the outlet valve, opening a first valve to selectively fluidly couple the water inlet to a first branch selectively fluidly coupled to the mold fluid inlet and a second branch electively fluidly coupled to the mold fluid inlet and including the switch.

9. The method of claim 1, further comprising: automatically closing, via a controller module of the casting system, the outlet valve; after closing the outlet valve, automatically opening, via the controller module, the first valve; and automatically determining, via the controller module, if the switch is opened or closed.

10. A casting system comprising: a mold having a mold fluid inlet and a mold fluid outlet; a water inlet selectively fluidly coupled to the mold fluid inlet through a first valve; an outlet valve provided downstream of and fluidly coupled to the mold fluid outlet; a switch provided downstream of the first valve and being selectively fluidly coupled to the mold fluid inlet, the switch being movable between an opened position and a closed position; and a controller module configured to detect a presence of or a non-presence of a leak within the mold by: closing the outlet valve; after closing the outlet valve, opening the first valve to direct a water from the water inlet into the mold through the mold fluid inlet; determining if the switch is opened or closed; if the switch is closed, determining the presence of a leak within the mold; and if the switch is opened, determining the non-presence of a leak within the mold.

11. The casting system of claim 10, further comprising: a first branch fluidly coupling the first valve to the mold fluid inlet; and a second branch fluidly coupling the first valve to the mold fluid inlet, the first branch and the second branch meeting at a junction downstream of the first valve, the second branch including the switch.

12. The casting system of claim 11, further comprising a second valve provided downstream of the junction.

13. The casting system of claim 10, further comprising a first check valve provided on the first branch and a second check valve provided on the second branch, upstream of the switch.

14. The casting system of claim 10, further comprising a gas inlet selectively fluidly coupled to the mold fluid inlet.

15. The casting system of claim 14, wherein if the leak is detected, the controller module is configured to: open a second valve to selectively fluidly couple a gaseous fluid through a gas inlet to the mold fluid inlet; close the outlet valve; supply a gaseous fluid to the mold through the mold fluid inlet; and purge the water within the casting system through the leak in the mold.

16. A method of casting, the method comprising: injecting a molten metal into a mold, the mold having a mold fluid inlet and a mold fluid outlet; impacting the mold; and directly before, in tandem with, or directly after impacting the mold: opening a first valve to selectively fluidly couple a water inlet to the mold through the mold fluid inlet in order to cool the molten metal within the mold; after opening the first valve, performing a gaseous fluid purge by: closing the first valve; and after closing the first valve, opening a second valve to selectively fluidly couple a gas to the mold through the mold fluid inlet; and impacting the mold once the gaseous fluid purge is completed.

17. The method of claim 16, further comprising: prior to closing the first valve, determining a heat of the mold by measuring a temperature of a fluid within the mold fluid inlet, and closing the first valve once the measured temperature is lower than a threshold temperature.

18. The method of claim 16, further comprising: determining if the gaseous fluid purge is desired; performing the gaseous fluid purge only if the gaseous fluid purge is desired; and if the gaseous fluid purge is not desired, closing the first valve and subsequently impacting the mold.

19. The method of claim 16, further comprising ejecting a fluid from a leak within the mold during the gaseous fluid purge.

20. The method of claim 16, further comprising opening, via a controller module, the first valve; after opening the first valve, performing, via the controller module, the gaseous fluid purge by: closing, via the controller module, the first valve; and opening, via the controller module, the second valve.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In the drawings:

[0023] FIG. 1 is a schematic illustration of a typical cold chamber die casting machine having a mold.

[0024] FIG. 2 is a schematic illustration of a typical cold chamber die casting die or mold.

[0025] FIG. 3 is a schematic illustration of a casting system suitable for use with the mold of FIG. 1A, the system being able to detect a leak from a leak formed along the mold.

[0026] FIG. 4 is a flowchart illustrating a method for the detection of a leak using the casting system of FIG. 3.

[0027] FIG. 5 is a schematic illustration of an exemplary casting system suitable for use with the mold of FIG. 1, the system being able to purge a liquid from a liquid line and the mold.

[0028] FIG. 6 is a flowchart illustrating a method for the purging of air using the casting system of FIG. 5.

DETAILED DESCRIPTION

[0029] Aspects of this disclosure are related to a method and system of detecting a leak and performing an air purge of a mold used during a casting process. At least aspects of the detection of the leak and the air purge methods and systems can be utilized in tandem with or independently from one another. As a non-limiting example, the casting process can be the casting process shown and described in FIGS. 1 and 2, however, it will be appreciated that the method and system for detecting a leak and the method and system for performing an air purge can be utilized with any suitable casting process. The casting process, specifically the casting process utilizing the method and systems described herein, can be utilized to create any suitable cast component such as, but not limited to, an automotive part.

[0030] As used herein, the term upstream refers to a direction that is opposite the fluid flow direction, and the term downstream refers to a direction that is in the same direction as the fluid flow. The term fore or forward means in front of something and aft or rearward means behind something. For example, when used in terms of fluid flow, fore/forward can mean upstream and aft/rearward can mean downstream.

[0031] Furthermore, as used herein, the term set or a set of elements can be any number of elements, including only one.

[0032] Further yet, as used herein, the term fluid or iterations thereof can refer to any suitable fluid that is used during the casting process such as, but not limited to, a liquid (e.g., water or a molten metal) or a gas (e.g., air).

[0033] Connection references (e.g., attached, coupled, secured, fastened, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

[0034] FIG. 3 is a schematic illustration of a casting system 100 suitable for use with the mold 202 of FIG. 1. The casting system 100 can include a mold 102. The mold 102, as a non-limiting example, can include at least one fault or leak 132. The leak 132 can be any suitable defect or break in the mold that allows for a fluid to pass through the leak 132, and thus into or out of the mold 102. As a non-limiting example, the leak 132 can be a physical crack provided along the mold 102. The leak 132 can be formed during a current or previous casting process as described herein. The casting system 100 is able to detect the presence of or non-presence of the leak 132.

[0035] The casting system 100 includes a gas inlet 104, a water inlet 106 and a fluid outlet 130. The gas inlet 104 is any suitable inlet configured to supply a fluid in gaseous form to the casting system 100. As a non-limiting example, the gas inlet 104 can be an air inlet that supplies air (e.g., ambient pressurized air) to the casting system. The water inlet 106 and the gas inlet 104 are each selectively and independently fluidly coupled to the mold 102 via a first valve 110 and a second valve 108, respectively. A first check valve 112 is provided downstream of the second valve 108 to ensure a fluid within the casting system 100 downstream of the first check valve 112 does not flow backwards and into the second valve 108. The first valve 110 is directly fluidly coupled to a first branch 134 and a second branch 136. A second check valve 114 is provided downstream of the first valve 110 along the first branch 134 to ensure a fluid within the casting system 100 downstream of the second check valve 114 does not flow backwards and into the first valve 110. A third check valve 116 is provided downstream of the first valve 110 along the second branch 136 to ensure a fluid within the casting system 100 downstream of the third check valve 116 does not flow backwards and into the first valve 110. While illustrated as including the first check valve 112, the second check valve 114 and the third check valve 116, it will be appreciated that the casting system 100 can include any number of check valves provided along any suitable portion of the casting system 100. It will be further appreciated that the casting system 100 can be formed without any check valve.

[0036] A switch 118 can be provided along the second branch 136 downstream of the second check valve 114. The switch 118 is a normally-off switch that can be latched or otherwise closed when water flows through the second branch 136 and through the third check valve 116.

[0037] The first branch 134 and the second branch 136 meet at a water junction 138 downstream the second check valve 114 and the third check valve 116. A third valve 120 is provided downstream of and directly fluidly coupled to the water junction 138. Alternatively, the first branch 134 and the second branch 136 can each be separately fluidly coupled to the third valve 120 such that the third valve 120 defines the water junction 138.

[0038] A fluid junction 140 is provided downstream the first check valve 112 and the third valve 120 and defines a location where the fluid from the gas inlet 104 can meet the fluid from the water inlet 106. As such, the portion of the casting system 100 downstream the fluid junction 140 can be defined by the presence of only water, only a gaseous fluid, or a mixture of water and gaseous fluid depending on which of the second valve 108, the first valve 110 or the third valves 120 are open.

[0039] A mold fluid inlet 122 can fluidly couple the fluid junction 140 to the mold 102. Alternatively, the fluid junction 140 can be formed at or within the mold 102 such that that the fluid junction 140 defines the mold fluid inlet 122. A mold fluid outlet 124 fluidly couples the mold to an outlet valve 126, which is ultimately fluidly coupled to the fluid outlet 130. A sensor 128 can be provided downstream of the outlet valve 126. The sensor 128 can be used for a multitude of reasons. As a non-limiting example, the sensor 128 can be used to measure the heat of the fluid exiting the casting system 100. As a non-limiting example, the sensor 128 can be used to determine the presence of or non-presence of a fluid (e.g., water and/or gaseous fluid).

[0040] The second valve 108, the first valve 110, the third valve 120, and the outlet valve 126 can be any suitable valve such as, but not limited to, a solenoid valve.

[0041] The casting system 100 can include a control system including a controller module 142 having a processor 144 and a memory 156 can be communicatively coupled to respective portions of the casting system 100 The memory 146 can be defined as an internal storage for various aspects of the casting system 100. For example, the memory 146 can store code, executable instructions, commands, instructions, authorization keys, specialized data keys, passwords, or the like. The memory 146 can be RAM, ROM, flash memory, or one or more different types of portable electronic memory, such as discs, DVDs, CD-ROMs, etc., or any suitable combination of these types of memory. The processor 144 can be defined as a portion of the controller module 142 which can receive an input, perform calculations, and output executable data. The processor 144 can be a microprocessor. The control system can be communicatively coupled to and control at least a portion of the casting system 100. As a non-limiting example, the second valve 108, the first valve 110, the third valve 120 and the outlet valve 126 can be selectively controlled via the control system. As a non-limiting example, the switch 118 can be monitored via the control system and determine if the switch 118 is opened or closed. As a non-limiting example, the control system can monitor the sensor 128 and send a communication to an exterior system to alert a user to the presence of or non-presence of the leak 132. As a non-limiting example, the exterior system can be an alarm, a light, a computer, a printer, a smartphone, or any other suitable system that can alert or otherwise inform a user of the casting system 100 to the presence of or non-presence of the leak 132.

[0042] During operation, the casting system 100 can be used to detect the presence of or non-presence of the leak 132 by performing the following operations.

[0043] To detect the presence of or non-presence of the leak 132 (e.g., a leak) the third valve 120 opens and the first valve 110 opens and directs the water from the water inlet 106 and through the second branch 136. The second valve 108, the first valve 110 leading to the first branch 134 and the outlet valve 126 are both closed. Meaning that the only way for the water to exit the casting system 100 would be through the leak 132. If there is the leak 132, the water will flow past the switch 118 (thus closing the switch 118), through the mold fluid inlet 122 and out the leak 132. If there is not a leak 132, the water will not flow through the casting system 100 and thus not close the switch 118. The switch 118 being closed indicates the leak 132 is present, while the switch 118 being open indicates the non-presence of the leak 132. As the engagement of the switch 118 is used to determine the presence of or non-presence of the leak 132, the switch 118 can be defined as a leak detector.

[0044] If the switch 118 is closed (e.g., the leak 132 is present), the casting system 100 can proceed with the casting process. However, the water that flowed through the casting system 100 to detect the leak 132 must first be purged from the casting system 100. This is done by opening the second valve 108 and closing the outlet valve 126, the first valve 110 and the third valve 120. The pressurized gaseous fluid will then flow through the casting system 100 and eject any residual water through the leak 132.

[0045] Once the residual water is removed, the casting process can resume by further opening the outlet valve 126 and allowing the pressurized gaseous fluid to flow through the mold fluid outlet 124 and out of the fluid outlet 130. The first, second, third, and outlet valves 110, 108, 120, 126 can then all be closed. During the metal injection, the first valve 110 is opened to allow water to flow through the first branch 134. The second valve 120 is further opened to allow for water, and only water, to flow into the mold fluid inlet 122. The outlet valve 126 is opened to allow for the water within the mold 102 to flow out the fluid outlet 130. This process is used as a method to cool the mold 102 and the molten metal during the casting process. The cooling of the mold 102 can be done for a period of time determined by the feedback or measurements from the sensor 128. As a non-limiting example, the sensor 128 can measure the heat leaving the casting system 100 through the mold fluid outlet 124. Once the temperature has heat removal reaches a predetermined threshold value, the cooling can stop and the process can resume as appropriate.

[0046] FIG. 4 is a flowchart illustrating a method 150 for the detection of a leak using the casting system 100 of FIG. 2.

[0047] The method 150 includes a series of normal casting procedures or is otherwise defined as the casting process. The casting process can include the pouring of a molten metal, at 152, injection of the metal into the mold 102, at 154, the impact of the mold 102, at 156, the opening of the die holding the mold 102, at 158, the extraction of the part formed by the mold 102, at 160, the spraying (e.g., with water) of the part, at 162, the blowoff of part, at 164, and the closing of the die, at 166.

[0048] The method 150, further includes a branch to detect the presence of or non-presence of the leak 192 along the mold 102. This detection branch occurs between spraying, at 162, and closing the die, at 166. As a non-limiting example, a leak test start can occur at 168 in tandem with, directly before or directly after the spray, at 162. The leak test (e.g., the detection of the leak described above) is performed, at 168, and ends, at 170. A decision is performed, at 172, to determine whether or not a leak was detected (e.g., whether or not the switch 118 is opened or closed). If the leak 132 has not formed, the process proceeds to the die closing, at 166. If, however, the leak 132 has formed the process moves to purge the residual water from the casting system 100 as described above, at 174. It is contemplated that an additional step of communicating the presence of the leak to a user of the casting system 100 can be performed after the leak 132 has been detected. Communicating the presence of the leak 132 can include alerting or otherwise informing the user of the leak 132. The user can further be presented with an option to proceed with the casting process (e.g., proceed to the die closing, at 166) or ending the process to fix the leak 132 and/or replace the mold 102.

[0049] FIG. 4 is a schematic illustration of an exemplary casting system 200 suitable for use with the mold 202 of FIG. 1A. The casting system 200 is similar to the casting system 100, therefore, like parts will be identified with like numerals further increased to the 200 series, with it being understood that description of like parts of the casting system 100 applies to the casting system 200, unless otherwise noted.

[0050] The casting system 200 includes a gas inlet 204 and a water inlet 206 that meet at a junction 240 defining or fluidly coupled to a mold fluid inlet 222 of the mold 202. A mold fluid outlet 224 is fluidly coupled to a fluid outlet 230 defining a fluid outlet of the casting system 200. A sensor 228 is provided along the mold fluid outlet 224. A first valve 210 selectively fluidly couples the water inlet 206 to the mold 202. A second valve 208 selectively fluidly couples the gas inlet 204 to the mold 202. A first check valve 212 is provided downstream the second valve 208. A second check valve 214 is provided downstream the first valve 210. The casting system 200 can include any number of check valves including no check valves. The mold 202 an include or not include a leak 232. The casting system 200 can be used to at least detect the presence of or non-presence of the leak 232. The casting system 200 can include a control system including a controller module 242 with a processor 244 and a memory 246.

[0051] The casting system 200 is similar to the casting system 100, except that the casting system 200, however, the casting system 200 does not detect the presence of or non-presence of the leak 232 but instead assumes that the leak 232 is always present. As such, during operation, a purge of residual water is always performed by opening the second valve 208 and closing the first valve 210. This is done so that if there is the leak 232, any residual water will be purged from the leak 232. Otherwise, if there is not the leak 232 the residual water within the casting system 200 is ejected through the fluid outlet 230. The residual water can come from the cooling water that is used when pouring the molten metal into the mold 202.

[0052] FIG. 5 is a flowchart illustrating a method 250 for the purging of air using the casting system of FIG. 4.

[0053] The method 250 can include a series of normal casting procedures or otherwise defined as the casting process. The casting process can include the pouring of a molten metal, at 252, injection of the metal into the mold 202, at 254, the impact of the mold 202, at 256, the opening of the die holding the mold 202, at 258, the extraction of the part formed by the mold 202, at 260, the spraying (e.g., with water) of the part, at 262, the blowoff of part, at 264, and the closing of the die, at 266.

[0054] The method 250 further includes purging the casting system 200 of any residual water from the casting system 200 and removing the heat from the casting system 200 associated with pouring the metal, at 254. During, after, or before impact, at 256, the first valve 210 is opened, at 276, to begin the cooling of the molten metal that was just poured, at 254. A check can be performed, at 278, to see whether or not a gaseous fluid purge is desired. The desire of the gaseous fluid purge can be set by a user or otherwise automatically assumed to be desired or not desired by the casting system 200. If the gaseous fluid purge is not desired, the standard logic of the second valve 208 and the first valve 210 (e.g., the second valve 208 is closed and the first valve 210 is opened) is performed, at 280, and the method 250 proceeds with opening the die, at 258. If the gaseous fluid purge is desired, however, another check is performed, at 282, to determine the heat exiting the system. This is done by measuring the heat of the fluid flowing across the sensor 228. If the heat exceeds a threshold value (e.g., the mold 202 needs further cooling), the flow of water continues through the casting system 200, at 286 until the heat is below the threshold value. If, however, the heat does not exceed the threshold value (e.g., the mold 202 does not need further cooling), the water stops being fed through the system by closing the first valve 210, at 284. In either case, once the heat drops below the threshold value, the gaseous fluid purge can begin, at 288, by performing the steps outlined previously. The gaseous fluid purge can end, at 290, and the method 250 can proceed back to the impact, at 256.

[0055] The sequence depicted in the method 150, 250 for illustrative purposes only and is not meant to limit the method 150, 250 in any way as it is understood that the portions of the method 150, 250 can proceed in a different logical order, additional or intervening portions can be included, or described portions of the method can be divided into multiple portions, or described portions of the method can be omitted without detracting from the described method. For example, the method 150, 250 can include various other steps such as alerting a user to the presence or non-presence of the leak.

[0056] As a non-limiting example, the method 150, 250 can include a method of automatically detecting the presence of or non-presence of a leak. The automatic performance of the method 150, 250 or parts of the method 150, 250 can be done through use of the control system, specifically the controller module 142, 242.

[0057] As a non-limiting example, the method 150 can include a branch to detect the presence of or non-presence of the leak 192 along the mold 102, via the controller module 142. The leak test (e.g., the detection of the leak described above) is performed, via opening and closing of valves via the controller module 142 or measurement or detection of values (e.g., of the switch 118) via the controller module 142, at 168, and ends, at 170. A decision can be performed, via the controller module 142, at 172, to determine whether or not a leak was detected (e.g., whether or not the switch 118 is opened or closed). If the leak 132 has not formed, the process proceeds to the die closing, via a command from the controller module 142, at 166. If, however, the leak 132 has formed the process moves to purge the residual water from the casting system 100 as described above, via a command from the controller module 142, at 174. It is contemplated that an additional step of communicating, via the controller module 142, the presence of the leak to a user of the casting system 100 can be performed after the leak 132 has been detected.

[0058] As a non-limiting example, the method 250 can include after, or before impact, at 256, the first valve 210 is opened, at 276, via the controller module 242, to begin the cooling of the molten metal that was just poured, at 254. A check can be performed, via the controller module 242, at 278, to see whether or not a gaseous fluid purge is desired. If the gaseous fluid purge is not desired, the standard logic of the second valve 208 and the first valve 210 (e.g., the second valve 208 is closed and the first valve 210 is opened) is performed, via the controller module 242, at 280, and the method 250 proceeds with opening the die, via the controller module 242, at 258. If the gaseous fluid purge is desired, however, another check is performed, via the controller module 242, at 282, to determine the heat exiting the system. This is done by measuring, via the controller module 242, the heat of the fluid flowing across the sensor 228. If it is determined, via the controller module 242, the heat exceeds a threshold value (e.g., the mold 202 needs further cooling), the flow of water continues through the casting system 200, at 286 until the heat is below the threshold value, via a command from the controller module 242. If, however, the heat does not exceed the threshold value (e.g., the mold 202 does not need further cooling), the water stops being fed through the system by closing the first valve 210, via a command from the controller module 242, at 284. In either case, once the heat drops below the threshold value, the gaseous fluid purge can begin, via the controller module 242, at 288, by performing the steps, via the controller module 242, outlined previously. The gaseous fluid purge can end, via the controller module 242, at 290, and the method 250 can proceed back to the impact, at 256.

[0059] Benefits of the present disclosure include a method and system for a casting process better suited for mitigating and detecting the presence of a leak when compared to a conventional casting process. For example, the conventional casting process relies on physical inspection of the mold or a failed casting in order to determine if a leak has formed. If the leak has occurred, the mold must be repaired or otherwise not used any more. During the conventional casting process, water or other fluid are used to cool the molten metal. If there is any residual water within the system that is not purged out (e.g., within the leak), then failure of the casting can occur when the molten metal comes into contact with the residual fluid that was used to cool the molten metal. The method and system, as described herein, however, is able to purge any residual fluid from the mold to ensure that even if there is a leak, there will not be any residual fluid within the leak or any other part of the mold such that the pouring of the molten metal can occur even if there is a leak. Using a mold with a leak formed within the mold is not feasible with the conventional casting process. Further, the method and system, as described herein, allows for the detection of the leak without the need for physical inspection of the mold and prior to the mold breaking, as would happen if a mold were used in the conventional casting process. The detection of the leak and the purging of the residual water, in turn, results in a method and system for a casting process better suited for mitigating and detecting the presence of a leak when compared to the conventional casting process.