DEVICE AND METHOD THAT CAN DETECT MISALIGNMENT BETWEEN COPE AND DRAG

Abstract

To provide a device and a method for detecting, before pouring starts, any misalignment between a cope and a drag that have been molded by a flaskless molding machine and then assembled. The device (40) that can detect any misalignment between the cope (2) and the drag (3) that have been molded by the flaskless molding machine (1) and then assembled and that are being transported to the position for pouring comprises a plurality of means (51), (52), (53) for measuring distances to the cope and the drag that measures the distances (S11), (S12), (S13), (S21), (S22), (S23) to the cope and the drag, and a means (48) for calculating a degree of a misalignment between the cope and the drag on a basis of the distances to the cope and the drag that have been measured by the means for measuring distances to the cope and the drag.

Claims

1. A device that can detect any misalignment between a cope and a drag that have been manufactured by means of a flaskless molding machine and assembled and that are being transported to a position for pouring, the device comprising: a plurality of means for measuring distances to the cope and the drag that measure distances to the cope and the drag; and a means for calculating a degree of a misalignment between the cope and the drag that calculates a degree of a misalignment between the cope and the drag on a basis of the distances to the cope and the drag as measured by the means for measuring distances to the cope and the drag.

2. The device that can detect any misalignment between the cope and the drag of claim 1, further comprising: a means for moving up and down that moves up and down the plurality of the means for measuring distances to the cope and the drag; wherein the device has three means for measuring distances to the cope and the drag, the three means for measuring distances to the cope and the drag measuring distances to points, which are on same levels of the cope and the drag, and wherein the three means for measuring distances to the cope and the drag are caused by the means for moving up and down to move to a level for measuring the cope and to a level for measuring the drag.

3. The device that can detect any misalignment between the cope and the drag of claim 2, wherein the cope and the drag are rectangular in each horizontal section, and wherein the three means for measuring distances to the cope and the drag are a first means for measuring distances to the cope and the drag, a second means for measuring distances to the cope and the drag, and a third means for measuring distances to the cope and the drag, wherein the first means for measuring distances to the cope and the drag measures the distances to the points, which are on first sides of the cope and drag, which sides are parallel to a conveying direction, respectively, wherein the second means for measuring distances to the cope and the drag measures the distances to the points, which are spaced apart from the points on the first sides by a predetermined distance in the horizontal direction, respectively, wherein the third means for measuring distances to the cope and the drag measures the distances to the points, which are on second sides of the cope and drag, which sides are perpendicular to the conveying direction, respectively.

4. The device that can detect any misalignment between the cope and the drag of claim 3, wherein the first means for measuring distances to the cope and the drag, the second means for measuring distances to the cope and the drag, and the third means for measuring distances to the cope and the drag, are laser-type displacement sensors.

5. A method that can detect any misalignment between the cope and the drag is a method to use the device of claim 3, the method comprising the steps of: moving the first means for measuring distances to the cope and the drag, the second means for measuring distances to the cope and the drag, and the third means for measuring distances to the cope and the drag to a level to measure the cope by the means for moving up and down; measuring a distance to the point on the first side of the cope by the first means for measuring distances to the cope and the drag; measuring a distance to the point on the first side of the cope by the second means for measuring distances to the cope and the drag; measuring a distance to the point on the second side of the cope by the third means for measuring distances to the cope and the drag; calculating a position in a horizontal plane and an angle of rotation in a horizontal direction of the cope by the means for calculating a degree of a misalignment between the cope and the drag based on the distance to the point on the first side of the cope measured by the first means for measuring distances to the cope and the drag, the distance to the point on the first side of the cope measured by the second means for measuring distances to the cope and the drag, and the distance to the point on the second side of the cope measured by the third means for measuring distances to the cope and the drag; moving the first means for measuring distances to the cope and the drag, the second means for measuring distances to the cope and the drag, and the third means for measuring distances to the cope and the drag to a level to measure the drag by the means for moving up and down; measuring a distance to the point on the first side of the drag by the first means for measuring distances to the cope and the drag; measuring a distance to the point on the first side of the drag by the second means for measuring distances to the cope and the drag; measuring a distance to the point on the second side of the drag by the third means for measuring distances to the cope and the drag; calculating a position in a horizontal plane and an angle of rotation in a horizontal direction of the drag by the means for calculating a degree of a misalignment between the cope and the drag based on the distance to the point on the first side of the drag measured by the first means for measuring distances to the cope and the drag, the distance to the point on the first side of the drag measured by the second means for measuring distances to the cope and the drag, and the distance to the point on the second side of the drag measured by the third means for measuring distances to the cope and the drag; 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 and the drag that have been calculated; and determining that a misalignment has occurred if the degree of misalignment is outside of a predetermined allowable range.

6. The method that can detect any misalignment between the cope and the drag of claim 5, wherein no molten metal is poured into the cope and the drag that have been determined to have a misalignment.

7. The method that can detect any misalignment between the cope and the drag of claim 5, wherein if a misalignment is determined to have occurred, then a molding operation by the flaskless molding machine is stopped.

8. The method that can detect any misalignment between the cope and the drag of claim 5, 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.

9. The method that can detect any misalignment between the cope and the drag of claim 5, 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 is adjusted.

10. The method that can detect any misalignment between the cope and the drag of claim 5, 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 or a molding line that conveys the cope and the drag from the flaskless molding machine to a position for pouring.

11. The method that can detect any misalignment between the cope and the drag of claim 5, 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.

12. The method that can detect any misalignment between the cope and the drag of claim 5, wherein if the degree of misalignment is within the allowable range, but not within a warning range, which is smaller than the allowable range, a predictor of a misalignment is displayed.

13. The device that can detect any misalignment between the cope and the drag of claim 1, wherein the cope and the drag are rectangular in each horizontal section, wherein the plurality of means for measuring distances to the cope and the drag are a first means for measuring distances to the cope, a second means for measuring distances to the cope, a third means for measuring distances to the cope, a first means for measuring distances to the drag, a second means for measuring distances to the drag, and a third means for measuring distances to the drag, wherein the first means for measuring distances to the cope measures the distance to the point, which is on a first side of the cope, which side is parallel to a direction for conveying the cope and the drag, wherein the second means for measuring distances to the cope measures the distance to the point, which is spaced apart from the point on the first side of the cope by a predetermined distance in the horizontal direction, wherein the third means for measuring distances to the cope measures the distance to the point, which is on a second side of the cope, which side is perpendicular to the direction for conveying the cope and the drag, wherein the first means for measuring distances to the drag measures the distance to the point, which is on a first side of the drag, which side is parallel to the direction for conveying the cope and the drag, wherein the second means for measuring distances to the drag measures the distance to the point, which is spaced apart from the point on the first side of the drag by a predetermined distance in the horizontal direction, wherein the third means for measuring distances to the drag measures the distance to the point, which is on a second side of the drag, which side is perpendicular to the direction for conveying the cope and the drag.

14. The device that can detect any misalignment between the cope and the drag of claim 1, wherein the cope and the drag are rectangular in each horizontal section, wherein the plurality of means for measuring distances to the cope and the drag are a first means for measuring distances to the cope, a first means for measuring distances to the drag, a second means for measuring distances to the cope, and a second means for measuring distances to the drag, wherein the first means for measuring distances to the cope measures a distance to a first side of the cope, which side is parallel to the direction for conveying the cope, wherein the first means for measuring distances to the drag measures a distance to a first side of the drag, which side is parallel to the direction for conveying the drag, wherein the second means for measuring distances to the cope measures a distance to a second side of the cope, which side is perpendicular to the direction for conveying the cope, wherein the second means for measuring distances to the drag measures a distance to a second side of the drag, which side is perpendicular to the direction for conveying the drag.

15. The device that can detect any misalignment between the cope and the drag of claim 14, wherein the first means for measuring distances to the cope and the first means for measuring distances to the drag are configured to be moved by means of an actuator in the direction for conveying the cope and the drag, and wherein the second means for measuring distances to the cope and the second means for measuring distances to the drag are configured to be moved by means of an actuator in a direction perpendicular to the direction for conveying the cope and the drag.

16. The device that can detect any misalignment between the cope and the drag of claim 14, wherein 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 configured to be able to he simultaneously moved up and down by an actuator.

17. The device that can detect any misalignment between the cope and the drag of claim 14, wherein 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.

18. A method that can detect any misalignment between the cope and the drag is a method to use the device of 14, the method comprising the steps of; measuring a distance to a first side of the cope by the first means for measuring distances to the cope; measuring a distance to a first side of the drag by the first means for measuring distances to the drag; measuring a distance to a second side of the cope by the second means for measuring distances to the cope; measuring a distance to a second side of the drag by the second means for measuring distances to the drag; and determining a misalignment that has occurred if a difference between the distance to the first side of the cope that is measured by the first means for measuring distances to the cope and the distance to the first side of the drag that is measured by the first means for measuring distances to the drag or a difference between the distance to the second side of the cope that is measured by the second means for measuring distances to the cope and the distance to the second side of the drag that is measured by the second means for measuring distances to the drag, is outside of an allowable range.

19. The method that can detect any misalignment between the cope and the drag of claim 18, wherein the first means for measuring distances to the cope and the first means for measuring distances to the drag are configured to be moved by means of an actuator in the direction for conveying the cope and the drag, wherein the second means for measuring distances to the cope and the second means for measuring distances to the drag are configured to be moved by means of an actuator in a direction perpendicular to the direction for conveying the cope and the drag, and wherein 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, continually measure distances to the respective sides of the cope and drag at intervals along at least parts of the sides.

20. The method that can detect any misalignment between the cope and the drag of claim 18, wherein no molten metal is poured into the cope and the drag that have been determined to have a misalignment.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0029] 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.

[0030] FIG. 2 is a view taken along the arrow A-A in FIG. 1.

[0031] FIG. 3 is a view taken along the arrow B-B in FIG. 1.

[0032] FIG. 4 is a schematic drawing that illustrates a measurement of a distance to a side of a cope.

[0033] FIG. 5 is a schematic drawing that illustrates a measurement of a distance to a side of a drag.

[0034] 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.

[0035] 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.

[0036] 81

[0037] FIG. 8 is a view taken along the arrow A-A in FIG. 7.

[0038] FIG. 9 is a view taken along the arrow B-B in FIG. 7.

[0039] 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.

[0040] 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.

MODE FOR CARRYING OUT THE INVENTION

[0041] Below, with reference to the drawings, embodiments of the present invention are discussed in detail. In FIGS. 1, 2, and 3 the reference number 1 denotes a flaskless molding machine. In this invention, 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.

[0042] At a position adjacent to the flaskless molding machine 1, 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.

[0043] At a position adjacent to the cope 2 and the drag 3 that are intermittently conveyed, a device 40 that can detect any misalignment between the cope 2 and the drag 3 is provided. Now, 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. Incidentally, 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, and the vertical direction is called a Z-direction.

[0044] 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. Incidentally, the cylinder 46, i.e., the actuator, can be any type, such as an electric type, an oil-pressure type, a water-pressure type, or an air-pressure type. Furthermore, 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.

[0045] 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 2i, 3i on the first sides 2a, 3a, 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 2j, 3j on the first sides 2a, 3a. The points 2j, 3j are located on the same level as the points 21, 31 and spaced apart from them by a predetermined distance. Here, 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 2k, 3k on the second sides 2b, 3b, which are perpendicular (the X-direction) to the direction for conveying the cope 2 and the drag 3. The points 2k, 3k are located on the same level as the points 2i, 3i and the points 2j, 3j.

[0046] 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 2i, 3i, 2j, 3j on the first sides 2a, 3a, 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 2k, 3k on the second sides of 2b, 3b. These sides are perpendicular to the frame 44 for moving up and down. By placing the first means 51, the second means 52, and the third means 53 in this way, the distances to three points, i.e., the positions, 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.

[0047] Since the cylinder 46 moves up and down the frame 44 for moving up and down, 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 2i, 2j, 2k of the cope 2 and to a set height to measure the points 3i, 3j, 3k of the drag 3. Thus 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.

[0048] The points 2i, 2j, 2k of the cope 2 and the points 3i, 3j, 3k 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 2i, 2j, 2k of the cope 2 may be the same as, or different from, that for the points 3i, 3j, 3k of the drag 3. For example, the points 2i, 2j, 2k are positioned at a level that is 100 mm higher than the parting plane 19. And the points 3i, 3j, 3k are positioned at a level that is 100 mm lower than the parting plane 19. Incidentally, 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. When the device 40 measures the distances, the height is then known.

[0049] 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 2i, 2j, 2k 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 3i, 3j, 3k 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. Incidentally, 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. Alternatively, it may be installed in a controller for another device such as the flaskless molding machine 1, the molding line 30 for conveying the cope 2 and the drag 3, and a pouring machine (not shown) that pours molten metal into the cope 2 and the drag 3. Namely, the means 48 for calculating may be a controller.

[0050] Preferably, 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.

[0051] Next, with further reference to FIGS. 4 and 5, a method that can detect any misalignment between the cope and the drag by using the device 40 is discussed. 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. When 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. Here, 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 2i, 2j, 2k of the cope 2 and to the three points 3i, 3j, 3k 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 2k, 3k on the second sides 2b, 3b. 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.

[0052] While the cope 2 and the drag 3 stop while being intermittently conveyed, 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 2i, 2j, 2k 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 S11 to the point 2i, the second means 52 measures the distance S12 to the point 2j, and the third means 53 measures the distance S13 to the point 2k. The measured distances S11, 512, S13 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.

[0053] After the first, second, and third means 51, 52, 53 have measured the distances to the three points 2i, 2j, 2k, 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 3i, 3j, 3k of the drag 3. Then the first means 51 measures the distance S21 to the point 3i, the second means 52 measures the distance S22 to the point 3j, and the third means 53 measures the distance S23 to the point 3k. 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 S21, S22, S23 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.

[0054] Incidentally, after the first, second, and third means 51, 52, 53 have measured the distances to the three points 3i, 3j, 3k, 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 2i, 2j, 2k of the cope 2, so that, the first, second, and third means 51, 52, 53 measure the distances S11, S12, S13 to the points 2i, 2j, 2k, respectively. Further, 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.

[0055] 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.

[0056] 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. Alternatively, if the distances at two or three or all four corners exceed the allowable range, then a misalignment may be determined to have occurred. 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.

[0057] After the operation for determining a misalignment by the device 40 is finished, the clamp on the bogie 4 with a molding board is released and the cope 2 and the drag 3 are again intermittently conveyed. Then a jacket (not shown) is capped on the cope 2 and the drag 3 and a weight is placed on them before pouring starts. Then molten metal is poured into the cope 2 and the drag 3 by the pouring machine (not shown). Incidentally, 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 2i, 2j, 2k, and 3i, 3j, 3k 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. Thus unless measuring the distances to the points 2i, 2j, 2k, 3i, 3j, 3k is disturbed by the jacket, the measurement can be performed after the jacket is capped.

[0058] If 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. Namely, 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.

[0059] If a misalignment is determined to have occurred as a result of detecting a misalignment, 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. Here 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.

[0060] If the misalignment is determined to have occurred as a result of detecting a misalignment, 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. 1), the initial velocity for pushing the bogie 4 with a molding board by means of a pusher (not shown) may be too fast. In this way, the causes of the misalignment can be predicted based on the direction of the misalignment between the cope 2 and the drag 3. By displaying the causes of the misalignment that have been identified, the operator can easily learn what devices are to be repaired, and so can easily resolve the causes of the misalignment. 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.

[0061] If a misalignment is determined to have occurred as a result of detecting a misalignment, 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. For example, if 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 (not shown) may be too fast. In this case the initial velocity of the device for pushing a mold out, which is the operating condition that causes the misalignment, is modified. Specifically, 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. If 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 (not shown) may be too fast. In this case the initial velocity of the pusher, which is the operating condition that causes the misalignment, is modified. Specifically, 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.

[0062] If no misalignment is determined to have occurred as a result of detecting a misalignment, 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. By storing the data in this way, if a defect is found in a product, and as it can be confirmed that no misalignment has occurred during molding, the cause of the defect is easily investigated. Incidentally, the data may be stored in the means 48 for calculating or in a controller for another device.

[0063] Further, 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.

[0064] Even when 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. In this case 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. Incidentally, 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.

[0065] Next, with reference to FIG. 6, a 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 2i, 2j on the first side 2a of the cope 2, the distance to the point 2k on the second side 2b of the cope 2, the distances to the points 3i, 3j on the first side 3a of the drag 3, and the distance to the point 3k on the second side 3b 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 2i, 2j, 2k 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 3i, 3j, 3k 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.

[0066] By 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 2i, 2j, 2k, 3i, 3j, 3k 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.

[0067] Next, with reference to FIGS. 7-11, a device 5 that can detect any misalignment between the cope and drag (hereafter, the device 5), which is a third embodiment, is discussed. 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 2a 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 3a 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.

[0068] 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 2b 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 3b 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.

[0069] 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.

[0070] By this embodiment, 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. By the embodiment the electric cylinders are used for the first cylinder 10, the second cylinder 13, and the third cylinder 15.

[0071] Below, the operations of the device that is constructed as discussed above are discussed. By a means for carrying in, which means is not shown, the bogie 4 with a molding board has been carried in the station 17 for carrying a mold in. Next, 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. Next, 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.

[0072] A misalignment between the cope 2 and the drag 3 is detected at the station 18 for detecting a misalignment. Now, detecting a misalignment between the cope 2 and the drag 3 is discussed in detail. First, 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.

[0073] Next, by activating the third cylinder 15 the frame 14 for moving up and down is moved up or down so that the position in the Z-direction is adjusted. By this embodiment 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. Thus, 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.

[0074] 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. Thus the height of the parting plane 19 can be known for every mold.

[0075] Next, by activating the first cylinder 10, the first means 8 for measuring and the first means 9 for measuring are moved back and forth in the Y-direction. In this embodiment the stroke L1 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. While moving forward in that movement, the distances in the X-direction to the sides of the cope 2 and the drag 3 are measured. Specifically, as in FIG. 11, the distance Si from the tip of the first means 8 for measuring to the first side 2a of the cope is measured by the first means 8 for measuring. The distance S2 from the tip of the first means 9 for measuring to the first side 3a of the drag is measured by the first means 9 for measuring.

[0076] In measuring the distances S1, S2, the distances to at least parts of the sides of the cope and the drag (within the range of the stroke L1 in this embodiment) are continually measured at predetermined intervals along the sides of the cope and the drag. By this embodiment, the distances are measured at every 1 mm interval along the sides. Incidentally, while moving backward in that movement the distances S1, S2 are not measured. The first means 8 for measuring and the first means 9 for measuring are moved back to the original positions.

[0077] Next, by activating the second cylinder 13, the second means 11 for measuring and the second means 12 for measuring are moved back and forth in the X-direction. In this embodiment the stroke L2 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. While moving forward in that movement the distances in the Y-direction to the sides of the cope 2 and the drag 3 are measured. Specifically, as in FIG. 10, the distance S3 from the tip of the second means 11 for measuring to the second side 2b of the cope is measured by the second means 11 for measuring. The distance S4 from the tip of the second means 12 for measuring to the second side 3b of the drag is measured by the second means 12 for measuring.

[0078] In measuring the distances S3, S4, the distances to at least parts of the sides of the cope and the drag (within the range of the stroke L2 in this embodiment) are continually measured at predetermined intervals along the sides of the cope and the drag. By this embodiment, the distances are measured at every 1 mm interval along the sides. Incidentally while moving backward in the reciprocating movement the distances S3, S4 are not measured. The second means 11 for measuring and the second means 12 for measuring are moved back to the original positions.

[0079] Next, 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. Then 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. On the cope 2 and the drag 3, which are 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.

[0080] Now, a method for detecting a misalignment from the measured distances S1, S2, S3, S4 is discussed in detail. First, the difference S5 between the distance S1 and the distance S2 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 S5 is outside of this range, then a misalignment is determined to have occurred. Also, the difference S6 between the distance S3 and the distance S4 is obtained. If the difference S6 is outside of the predetermined range, then a misalignment is determined to have occurred. As an example in this embodiment, the reference value is 2 mm and the allowable range is 0.5 mum. Thus the predetermined range is 1.5-2.5 mm. If the difference S6 is outside of this range, then a misalignment is determined to have occurred. Incidentally, 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.

[0081] By this embodiment, as discussed above, the distances S1, S2, S3, S4 are measured at every 1 mm interval along the sides of the cope and the drag. Thus the differences S5, S6 are obtained multiple times. The difference that is used for determining a misalignment can be arbitrarily selected from the differences S5, S6 that are continually obtained multiple times. For example, if one of the differences S5, S6 is outside of the predetermined range, then a misalignment is determined to have occurred. For another example, if both differences S5, S6 that are continually obtained multiple times are outside of the predetermined range, then a misalignment is determined to have occurred. As discussed above, by the device 5, since a misalignment is determined to have occurred by using differences at multiple points along the sides 2a, 2b, 3a, 3b of the cope 2 and the drag 3, a misalignment can be reliably determined to have occurred.

[0082] 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.

[0083] Incidentally, by the present invention, 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. Further, 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. By this configuration, since the distances to the sides of the cope and the drag can be continually measured at predetermined intervals along the sides, a lot of data that are measured and that are used for determining a misalignment can be obtained. Thus any trend in misalignments can be advantageously found.

[0084] By the present invention, 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. By this configuration, the positions in the Z-direction can be advantageously adjusted within a short period of time.

[0085] Further, by the present invention, 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. By this configuration, the distances to the sides of the cope and drag can be correctly measured. Further, the device can be made to be compact.

[0086] Further, by the present invention, if the difference S5 between the distance S1 to the first side 2a of the cope as measured by the first means 8 for measuring and the distance S2 to the first side 3a of the drag as measured by the first means 9 for measuring or the difference S6 between the distance S3 to the second side 2b of the cope as measured by the second means 11 for measuring and the distance S4 to the second side 3b 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. By this configuration, 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.

[0087] Further, by the present invention, 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. By this configuration, a lot of data that are measured and that are used for determining a misalignment can be obtained along the sides of the cope and the drag. Thus any trend in misalignments can be advantageously found.

[0088] Further, by the present invention, no molten metal is poured into the cope 2 and the drag 3 that have been determined to have a misalignment. By this configuration, advantageously the amount of molten metal can be reduced and a useless product with a defect can be prevented.

[0089] By the embodiment of the present invention, after the first means 8 for measuring and the first means 9 for measuring are moved back and forth in the Y-direction by means of the first cylinder 10, 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. However, the order of the movements is not limited to the above. They may be moved in the reverse order or at the same time.

[0090] By the embodiment of the present invention, the distances S1, S2, S3, S4 are continually measured at the predetermined intervals along at least parts of the sides of the cope and the drag. However, 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.

[0091] Further, by the embodiment of the present invention, if either of the differences S5, S6 is outside of the predetermined allowable range, a misalignment is determined to have occurred. However, the determination is not limited to the above. Only if both of the differences S5, S6 are outside of the predetermined allowable range may a misalignment be determined to have occurred.

[0092] Further, by the embodiment of the present invention, the device 5 is located downstream of the station 17 for carrying a mold in by a pitch. However, 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.

[0093] Further, by the embodiment of the present invention, 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.

[0094] By the above discussion, 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. However, 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. Further, 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.

[0095] Below, the main reference numerals and s boils that are used in the detailed description and drawings are listed. [0096] 1 the flaskless molding machine [0097] 2 the cope [0098] 2a the first side of the cope [0099] 2b the second side of the cope [0100] 2i, 2j, 2k the points for measuring the distances to the cope [0101] 3 the drag [0102] 3a the first side of the drag [0103] 3b the second side of the drag [0104] 3i, 3j, 3k the points for measuring the distances to the drag [0105] 4 the bogie with a molding board [0106] 5 the device that can detect any misalignment between the cope and the drag [0107] 6 the direction for carrying out (the cope and the drag from the flaskless molding machine) [0108] 7 the conveying direction of (the cope and the drag) [0109] 8 the first means for measuring distances to the cope [0110] 9 the first means for measuring distances to the drag [0111] 10 the first cylinder (the actuator) [0112] 11 the second means for measuring distances to the cope [0113] 12 the second means for measuring distances to the drag [0114] 13 the second cylinder (the actuator) [0115] 14 the frame for moving up and down [0116] 15 the third cylinder (the actuator) [0117] 16 the supporting frame [0118] 17 the station for carrying a mold in [0119] 18 the station for detecting a misalignment [0120] 19 the parting plane [0121] 20 the rail [0122] 21 the base [0123] 22 the frame [0124] 30 the molding line [0125] 40 the device that can detect any misalignment between the cope and the drag [0126] 42 the supporting frame [0127] 44 the frame for moving up and down [0128] 46 the cylinder (the actuator) [0129] 48 the controller (the means for calculating the degree of a misalignment between the cope and the drag) [0130] 51 the first means for measuring distances to the cope and the drag [0131] 52 the second means for measuring distances to the cope and the drag [0132] 53 the third means for measuring distances to the cope and the drag [0133] 60 the device that can detect any misalignment between the cope and the drag [0134] 62 the supporting frame [0135] 64, 66 the horizontal frame [0136] 71 the first means for measuring distances to the cope [0137] 72 the second means for measuring distances to the cope [0138] 73 the third means for measuring distances to the cope [0139] 74 the first means for measuring distances to the drag [0140] 75 the second means for measuring distances to the drag [0141] 76 the third means for measuring distances to the drag [0142] S1 the distance to the first side of the cope [0143] S2 the distance to the first side of the drag [0144] S3 the distance to the second side of the cope [0145] S4 the distance to the second side of the drag [0146] S5 the difference between the distance to the first side of the cope and the distance to the first side of the drag [0147] S6 the difference between the distance to the second side of the cope and the distance to the second side of the drag [0148] S11 the distance from the first means for measuring distances to the cope and the drag to the point on the first side of the cope [0149] S12 the distance from the second means for measuring distances to the cope and the drag to the point on the first side of the cope [0150] S13 the distance from the third means for measuring distances to the cope and the drag to the point on the second side of the cope [0151] S21 the distance from the first means for measuring distances to the cope and the drag to the point on the first side of the drag [0152] S22 the distance from the second means for measuring distances to the cope and the drag to the point on the first side of the drag [0153] S23 the distance from the third means for measuring distances to the cope and the drag to the point on the second side of the drag