U.S. patent application number 16/962536 was filed with the patent office on 2020-12-03 for green sand mold forming sensor and green sand mold formability evaluation method.
This patent application is currently assigned to SINTOKOGIO, LTD.. The applicant listed for this patent is SINTOKOGIO, LTD.. Invention is credited to Yasuaki ASAOKA, Hisashi HARADA, Takato ISHII, Takehiro SUGINO.
Application Number | 20200376541 16/962536 |
Document ID | / |
Family ID | 1000005051317 |
Filed Date | 2020-12-03 |
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United States Patent
Application |
20200376541 |
Kind Code |
A1 |
ISHII; Takato ; et
al. |
December 3, 2020 |
GREEN SAND MOLD FORMING SENSOR AND GREEN SAND MOLD FORMABILITY
EVALUATION METHOD
Abstract
A green sand mold molding sensor that can measure the pressure
applied to a parting plane of a green sand mold in order to
determine the quality (casting mold strength) of a molded green
sand mold. A green sand mold molding sensor including a pressure
sensor for evaluating the molding properties of a green sand mold
molded by a casting mold molding machine, wherein the pressure
sensor is embedded in a plate having a model attached thereto.
Inventors: |
ISHII; Takato;
(Toyokawa-shi, JP) ; ASAOKA; Yasuaki;
(Toyokawa-shi, JP) ; HARADA; Hisashi;
(Toyokawa-shi, JP) ; SUGINO; Takehiro;
(Toyokawa-shi, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SINTOKOGIO, LTD. |
Nagoya-shi, Aichi |
|
JP |
|
|
Assignee: |
SINTOKOGIO, LTD.
Nagoya-shi, Aichi
JP
|
Family ID: |
1000005051317 |
Appl. No.: |
16/962536 |
Filed: |
April 25, 2019 |
PCT Filed: |
April 25, 2019 |
PCT NO: |
PCT/JP2019/017576 |
371 Date: |
July 16, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22C 11/10 20130101;
B22C 19/04 20130101; B22C 9/02 20130101 |
International
Class: |
B22C 19/04 20060101
B22C019/04; B22C 11/10 20060101 B22C011/10; B22C 9/02 20060101
B22C009/02 |
Foreign Application Data
Date |
Code |
Application Number |
May 7, 2018 |
JP |
2018-089064 |
Claims
1. A green sand mold molding sensor comprising a pressure sensor
for evaluating moldability of a green sand mold molded by a casting
mold molding machine, wherein the pressure sensor is embedded in a
plate having a model attached thereto.
2. The green sand mold molding sensor according to claim 1, wherein
the plate having the model attached thereto is a member that
constitutes a part of a boundary of a molding space defined by the
plate and a metal flask during green sand mold molding by the
casting mold molding machine.
3. The green sand mold molding sensor according to claim 1, wherein
a pressure-receiving surface of the pressure sensor and a surface
of the plate are in a flush state.
4. The green sand mold molding sensor according to claim 1, wherein
the pressure sensor is embedded between the wall of the metal flask
and the model in the plate at the time of green sand mold
molding.
5. The green sand mold molding sensor according to claim 1, wherein
the plate is configured to be rectangular, a plurality of the
pressure sensors are provided, and these pressure sensors are
embedded in the four corners of the plate.
6. The green sand mold molding sensor according to claim 1, wherein
the plate having the model attached thereto is divided into a
central part having the model attached thereto and a peripheral
part having the pressure sensor embedded therein, and the central
part of the plate having the model attached thereto is configured
so as to be attachable and detachable.
7. The green sand mold molding sensor according to claim 1, wherein
the casting mold molding machine is a flask molding machine and the
plate is placed on a carrier.
8. The green sand mold molding sensor according to claim 1, wherein
the casting mold molding machine is a flaskless molding machine and
the model is attached to both surfaces of the plate.
9. The green sand mold molding sensor according to claim 8, wherein
the casting mold molding machine is a flaskless molding machine and
the plate is placed on a shuttle dolly.
10. The green sand mold molding sensor according to claim 1,
wherein the pressure sensor is fixed to the plate by a screwing
means.
11. The green sand mold molding sensor according to claim 1,
wherein the pressure sensor is a fluid sensor.
12. The green sand mold molding sensor according to claim 1,
wherein the pressure sensor has a pressure-receiving surface that
is 5-30 mm in diameter.
13. A method for evaluating green sand mold moldability, wherein
moldability of a green sand mold molded by a casting mold molding
machine is evaluated by using a green sand mold molding sensor
comprising a pressure sensor embedded in a plate having a model
attached thereto.
Description
TECHNICAL FIELD
[0001] The present invention is related to a green sand mold
molding sensor that evaluates the moldability of a green sand mold
molded by a casting mold molding machine.
BACKGROUND
[0002] One of the qualities demanded of a green sand mold (casting
mold) molded by a casting mold molding device is casting mold
strength. Normally, in order to determine whether a molded green
sand mold has sufficient casting mold strength, work is carried out
to measure each molded green sand mold individually using a casting
mold strength gauge. A method for confirming whether a molded green
sand mold has sufficient casting mold strength without having to
perform such work is desired. Furthermore, a method for managing
the casting mold quality of each molded green sand mold without
stopping a process is desired.
[0003] For example, Patent Document 1 discloses a method for
detecting abnormalities in blowing in and filling of casting sand
in a blow-in type casting mold molding machine, wherein an internal
pressure is measured by a pressure sensor in order to detect
abnormalities in blowing in and filling of casting sand.
[0004] Further, Patent Document 2 discloses a molding device
monitoring system which discovers defective casting molds by using
position sensors for measuring positions of frame-setting
cylinders, filling-frame cylinders, and a leveling frame to monitor
the height of a parting plane of a casting mold.
CITATION LIST
Patent Literature
[0005] Patent Document 1: JP 3415497 B
[0006] Patent Document 2: JP 3729197 B
SUMMARY OF INVENTION
Technical Problem
[0007] However, the method for detecting abnormalities in blowing
in and filling of casting sand of Patent Document 1 is capable of
detecting sand filling defects only and it is difficult to confirm
the precise casting mold strength. Further, even if the molding
device monitoring system of Patent Document 2 monitors the height
of the parting plane of the casting mold, it is difficult to
confirm the precise casting mold strength from the height of the
parting plane.
[0008] The present invention was achieved in light of the foregoing
and has the objective of providing a green sand mold molding sensor
that can measure pressure applied to a parting plane of a green
sand mold in order to determine the quality (casting mold strength)
of a molded green sand mold.
Solution to Problem
[0009] In order to solve the problem mentioned above and achieve
the objective, the green sand mold molding sensor of the present
invention comprises a pressure sensor for evaluating the
moldability of a green sand mold molded by a casting mold molding
machine, wherein the pressure sensor is embedded in a plate having
a model attached thereto.
[0010] Further, in one embodiment of the present invention, the
plate having the model attached thereto is a member that
constitutes a part of a boundary of a molding space defined by the
plate and a metal flask during green sand mold molding by the
casting mold molding machine.
[0011] Further, in one embodiment of the present invention, a
pressure-receiving surface of the pressure sensor and a surface of
the plate are in a flush state.
[0012] Further, in one embodiment of the present invention, the
pressure sensor is embedded between the wall of the metal flask and
the model in the plate at the time of green sand mold molding.
[0013] Further, in one embodiment of the present invention, the
plate is configured to be rectangular, a plurality of the pressure
sensors are provided, and these pressure sensors are embedded in
the four corners of the plate.
[0014] Further, in one embodiment of the present invention, the
plate having the model attached thereto is divided into a central
part having the model attached thereto and a peripheral part having
the pressure sensor embedded therein, and the central part of the
plate having the model attached thereto is configured so as to be
attachable and detachable.
[0015] Further, in one embodiment of the present invention, the
casting mold molding machine is a flask molding machine and the
plate is placed on a carrier.
[0016] Further, in one embodiment of the present invention, the
casting mold molding machine is a flaskless molding machine and the
model is attached to both surfaces of the plate.
[0017] Further, in one embodiment of the present invention, the
casting mold molding machine is a flaskless molding machine and the
plate is placed on a shuttle dolly.
[0018] Further, in one embodiment of the present invention, the
pressure sensor is fixed to the plate by a screwing means.
[0019] Further, in one embodiment of the present invention, the
pressure sensor is a fluid sensor.
[0020] Further, in one embodiment of the present invention, the
size of the pressure-receiving surface of the pressure sensor is
5-30 mm in diameter.
[0021] Further, a method for evaluating green sand mold moldability
in the present invention evaluates moldability of a green sand mold
molded by a casting mold molding machine by using a green sand mold
molding sensor provided with a pressure sensor embedded in a plate
having a model attached thereto.
Effects of Invention
[0022] According to the present invention, an effect is exhibited
wherein it is possible to measure the pressure applied to a parting
plane of a green sand mold in order to determine the quality
(casting mold strength) of a molded green sand mold.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 represents a schematic of a structure of a casting
mold molding device using green sand mold molding sensors according
to a first embodiment.
[0024] FIG. 2 represents a configuration of a portion of a casting
mold molding device, wherein the portion evaluates casting mold
quality.
[0025] FIG. 3 is a cross-section view representing details of a
portion of a plate having green sand mold molding sensors embedded
therein.
[0026] FIG. 4 is a cross-section view representing details of a
portion of a plate having green sand mold molding sensors embedded
therein.
[0027] FIG. 5 is a block diagram representing one example of a
functional configuration of a casting mold quality evaluation
device.
[0028] FIG. 6 is a block diagram representing another example of a
functional configuration of a casting mold quality evaluation
device.
[0029] FIG. 7 is a schematic view representing a configuration of
an experiment carried out herein.
[0030] FIG. 8 is a graph representing one example of results
obtained by recording, in an integrated amplifier-recorder,
temporal changes in the pressure of a green sand mold molding
sensor in a squeezing step and analyzing by computer.
[0031] FIG. 9 is a graph summarizing a relationship between peak
pressure of a green sand mold molding sensor and casting mold
strength.
[0032] FIG. 10 shows one example of a screen displayed on a display
unit.
[0033] FIG. 11 shows one example of a screen displayed on a display
unit.
[0034] FIG. 12 shows one example of a screen displayed on a display
unit.
[0035] FIG. 13 shows steps in a method for evaluating casting mold
quality (method for molding a green sand mold) using the casting
mold molding device according to the first embodiment.
[0036] FIG. 14 shows another example of a plate having green sand
mold molding sensors embedded therein.
[0037] FIG. 15 shows another example of a plate having green sand
mold molding sensors embedded therein.
[0038] FIG. 16 shows a different mode of a plate.
[0039] FIG. 17 represents a schematic of a structure of a casting
mold molding device using green sand mold molding sensors according
to a second embodiment.
[0040] FIG. 18 represents a configuration of a portion of a casting
mold molding device, wherein the portion evaluates casting mold
quality.
[0041] FIG. 19 shows steps in a method for evaluating casting mold
quality (method for molding a green sand mold) using the casting
mold molding device according to the second embodiment.
[0042] FIG. 20 shows another example of a plate having green sand
mold molding sensors embedded therein.
[0043] FIG. 21 shows another example of a plate having green sand
mold molding sensors embedded therein.
[0044] FIG. 22 represents a schematic of a plate structure
according to the second embodiment.
DESCRIPTION OF EMBODIMENTS
[0045] Hereinafter, reference is made to the attached drawings to
describe embodiments for implementing the green sand mold molding
sensor and the method for evaluating green sand mold moldability
according to the present invention.
First Embodiment
[0046] The first embodiment will be described with reference to the
attached drawings. FIG. 1 represents a schematic of a structure of
a casting mold molding device using green sand mold molding sensors
according to the first embodiment and FIG. 2 represents a
configuration of a portion of the casting mold molding device,
wherein the portion evaluates casting mold quality. The casting
mold molding device according to the present embodiment is a flask
molding machine in which, after a green sand mold (casting mold) is
molded, a casting frame (metal frame), with the green sand mold
contained therein, transfers to the next step.
[0047] A casting mold molding device 1 comprises a plate 2 having a
model 3 attached to an upper surface thereof, a carrier 4, a metal
frame 5, a filling frame 6, a squeeze head 7, a squeeze board 8, a
table 9, green sand mold molding sensors 10A, 10B, 10C, 10D, wiring
11, and a casting mold quality evaluation device 12. Note that FIG.
2 represents the plate 2, the model 3, the carrier 4, and the green
sand mold molding sensors 10A, 10B, 10C, 10D as seen when viewed
from the upper side of the casting mold molding device 1.
[0048] The plate 2 has attached to an upper surface thereof an
upper mold (or lower mold) model 3 for molding a shape of a casting
in a green sand mold and is rectangular. The plate 2 is formed from
aluminum, for example. The carrier 4 is frame shaped and the plate
2 is placed inside the frame. In addition, green sand for molding a
green sand mold is filled into a casting mold molding space
surrounded by the plate 2, the metal frame 5, the filling frame 6,
and the squeeze board 8. The plate 2 is a member that constitutes a
part of a boundary of the molding space defined by the metal frame
5 during green sand mold molding by the casting mold molding device
1.
[0049] For the filling of green sand by the casting mold molding
device 1, a gravity drop method that uses the weight of the green
sand or a blowing method that uses an airflow is employed. The
gravity drop method is a method for filling green sand into the
casting mold molding space by causing green sand accumulated in a
louvered hopper (not shown) disposed at an upper portion of the
casting mold molding device 1 to drop due to gravity. Further, the
blowing method is a method for filling green sand by blowing green
sand inside a sand tank (not shown) into the casting mold molding
space.
[0050] Here, there follows a brief description of a procedure for
loading green sand into the casting mold molding space and
compressing. First, the metal frame 5 is placed on top of the
carrier 4 and then the filling frame 6 is overlaid on top of the
metal frame 5 to define the casting mold molding space. Next, green
sand is loaded into the casting mold molding space and the squeeze
board 8 compresses (squeezes) the green sand. Due thereto, the
green sand in the casting mold molding space is tamped and a green
sand mold is molded.
[0051] (Green Sand Mold Molding Sensor)
[0052] The green sand mold molding sensors 10A, 10B, 10C, 10D
measure, during molding of a green sand mold, a pressure value
(peak pressure) applied to a parting plane which is a joining
section between the plate 2 and an upper mold (or a lower mold)
comprising green sand formed inside the casting mold molding space.
The green sand mold molding sensors 10A, 10B, 10C, 10D are pressure
sensors. In the present embodiment, the green sand mold molding
sensors 10A, 10B, 10C, 10D are embedded in the four corners of the
plate 2. The reason, which is described later, that the green sand
mold molding sensors 10A, 10B, 10C, 10D are embedded in such a way
is a result of considering the variation in pressure applied within
a plate. By embedding the green sand mold molding sensors 10A, 10B,
10C, 10D in the four corners of the plate 2, it is possible to see
the strength distribution of the entire casting mold.
[0053] In addition, the green sand mold molding sensors 10A, 10B,
10C, 10D have a pressure-receiving surface for measuring pressure
that is exposed in the upper surface of the plate 2 and measures
the pressure value (peak pressure) applied to the parting plane
with the green sand mold. At this time, it is desirable for the
pressure-receiving surface of the green sand mold molding sensors
10A, 10B, 10C, 10D and the upper surface of the plate 2 to be in a
flush state with no differences in level therebetween. Due thereto,
it is possible to measure the precise pressure. In one example, the
green sand mold molding sensors 10A, 10B, 10C, 10D are fluid
pressure sensors. An earth pressure sensor may also be used as the
green sand mold molding sensors 10A, 10B, 10C, 10D.
[0054] Further, regarding the green sand mold molding sensors 10A,
10B, 10C, 10D, a small pressure-receiving surface is desirable,
considering the size of the plate 2 in which the sensors are
embedded and the size of the model 3, and moreover, that, as
described later, the casting mold strength of a green sand mold is
measured by a casting mold strength gauge at a position where the
green sand mold molding sensors 10A, 10B, 10C, 10D measure a
pressure and that a relationship between the pressure value (peak
pressure) and the casting mold strength is utilized. Meanwhile,
since measurement accuracy is also demanded, with respect to the
size of the pressure-receiving surface, a diameter of approximately
5-30 mm is desirable.
[0055] FIG. 3 and FIG. 4 are lateral cross-section views
representing details of a portion of the plate 2 that has green
sand mold molding sensors 10A, 10B, 10C, 10D embedded therein. FIG.
3 represents a case wherein the green sand mold molding sensors
10A, 10B, 10C, 10D are of a threaded type. As shown in FIG. 3, a
male thread is formed in a of the green sand mold molding sensors
10A, 10B, 10C, 10D, a female thread is formed in b of the plate 2,
and the green sand mold molding sensors 10A, 10B, 10C, 10D are
screwed to the plate 2.
[0056] Meanwhile, FIG. 4 represents a case wherein the green sand
mold molding sensors 10A, 10B, 10C, 10D are of a disk shape. As
shown in FIG. 4, the green sand mold molding sensors 10A, 10B, 10C,
10D, are placed in a hole in the plate 2 and a ring-shaped liner 13
surrounds the outer edge of the green sand mold molding sensors
10A, 10B, 10C, 10D. In addition, bolts 14 fix the liner 13 and
retain the green sand mold molding sensors 10A, 10B, 10C, 10D.
[0057] Thus, for the green sand mold molding sensors 10A, 10B, 10C,
10D, it is possible to use an object having a specification of
either a threaded type or a disk shape and that selection may be
made with consideration be given to an embedding space and
attachability of the green sand mold molding sensors.
[0058] The wiring 11 connects the casting mold quality evaluation
device 12 to the green sand mold molding sensors 10A, 10B, 10C,
10D. In the present embodiment, the green sand mold molding sensors
10A, 10B, 10C, 10D and the casting mold quality evaluation device
12 are connected by wire (wired communication) via the wiring 11
but may also be connected wirelessly (wireless communication). For
example, it is possible to amplify, by means of an amplifier, for
example, the pressure value (pressure value data) detected by the
green sand mold molding sensors 10A, 10B, 10C, 10D and use wireless
communication such as a wireless LAN or Bluetooth.RTM., etc., to
transmit from a transmitter to the casting mold quality evaluation
device 12.
[0059] (Casting Mold Quality Evaluation Device)
[0060] The casting mold quality evaluation device 12 evaluates the
quality of a green sand mold molded by the casting mold molding
device 1 from the pressure value (pressure value data) measured by
the green sand mold molding sensors 10A, 10B, 10C, 10D. FIG. 5 is a
block diagram representing a functional configuration of the
casting mold quality evaluation device 12 for wired communication
data. The casting mold quality evaluation device 12 comprises a
receiving unit 15, an amplification unit 16, an input unit 17, a
casting mold strength calculation unit 18, a casting mold quality
determination unit 19, a display unit 20, a transmission unit 21,
and a recording unit 22.
[0061] The receiving unit 15 receives the pressure value (pressure
value data) measured by the green sand mold molding sensors 10A,
10B, 10C, 10D. In the present example, wired data is received from
the wiring 11.
[0062] The amplification unit 16 amplifies the signal amount of the
received pressure value (pressure value data). The amplification
unit 16 is, for example, an amplifier.
[0063] The input unit 17 inputs: the casting mold strength of a
molded green sand mold measured by a casting mold strength gauge;
values of a slope "a" and an intercept "b" in an expression y=ax+b
described later; and a threshold value of the casting mold strength
of a green sand mold to be molded. Note that inputting is carried
out by a worker. The input unit 17 is, for example, a keyboard or a
touch panel. In the expression y=ax+b, "y" is the casting mold
strength and "x" is the pressure value measured by the green sand
mold molding sensors 10A, 10B, 10C, 10D. The expression is a
relational expression for determining the casting mold strength "y"
from the slope "a" and the intercept "b" which were inputted and a
measured value "x".
[0064] From the slope "a" and the intercept "b", which were
inputted into the input unit 17, and from the pressure value (peak
pressure) measured by the green sand mold molding sensors 10A, 10B,
10C, 10D, the casting mold strength calculation unit 18 calculates
the casting mold strength for each pressure value (peak pressure)
measured by the green sand mold molding sensors 10A, 10B, 10C, 10D
by using the relational expression between the measured value and
the casting mold strength. A method for calculating the casting
mold strength is described in detail later. The casting mold
strength calculation unit 18 is, for example, a computer or a
PLC.
[0065] The casting mold quality determination unit 19 determines
the quality of a molded green sand mold from the threshold value of
the casting mold strength inputted into the input unit 17 and the
calculated casting mold strength. A method for determining the
casting mold quality is described in detail later. The casting mold
quality determination unit 19 is, for example, a computer ora
PLC.
[0066] The display unit 20 displays: the pressure value (peak
pressure) measured by the green sand mold molding sensors 10A, 10B,
10C, 10D; values of the slope "a" and the intercept "b" in the
relational expression y=ax+b between the casting mold strength
inputted by a worker using the input unit 17 and the pressure value
(peak pressure); the threshold value of the casting mold strength
of a green sand mold to be molded that was inputted by a the
worker; a casting mold strength calculation result; and a casting
mold quality determination result, etc. The display unit 20 is, for
example, a liquid crystal display, etc.
[0067] The transmission unit 21 transmits fault-determination data
to a Patlite.RTM. 23, etc. Transmission may be either by wired data
or wireless data. In addition, a worker that has recognized a
defect occurrence in a green sand mold by confirming that the
Patlite 23 is flashing, etc., is to make an X mark on the relevant
green sand mold and thereby make it possible to understand at a
glance that that green sand mold is a defective product. A green
sand mold that has been recognized as being a defective product
does not undergo subsequent steps (molten metal pouring) and after
skipping these steps is finally shaken out from the mold.
[0068] The recording unit 22 records pressure value data, casting
mold strength data associated with pressure values, casting mold
strength calculation results, and casting mold quality
determination results, etc. Furthermore, these data are recorded
for each model attached to the plate 2. The recording unit 22 is,
for example, a recording medium such as a semiconductor memory or a
magnetic disk, etc. In addition, the data recorded by the recording
unit 22 may be extracted by using a USB memory or an SD card,
etc.
[0069] As described earlier, the green sand mold molding sensors
10A, 10B, 10C, 10D and the casting mold quality evaluation device
12 may be connected wirelessly (wireless communication). FIG. 6 is
a block diagram representing a functional configuration in the case
wherein the pressure value (pressure value data) measured by the
green sand mold molding sensors 10A, 10B, 10C, 10D is connected
wirelessly (wireless communication) to the casting mold quality
evaluation device 12. The pressure value (pressure value data)
measured by the green sand mold molding sensors 10A, 10B, 10C, 10D
is amplified by an amplification unit 16' near the green sand mold
molding sensors and wirelessly transmitted from a pressure value
transmission unit 24 to a receiving unit 15' of the casting mold
quality evaluation device 12. The casting mold quality evaluation
device 12 for wireless data shown in FIG. 6 comprises a receiving
unit 15', the input unit 17, the casting mold strength calculation
unit 18, the casting mold quality determination unit 19, the
display unit 20, the transmission unit 21, and the recording unit
22.
[0070] After the pressure value (pressure value data) measured by
the green sand mold molding sensors 10A, 10B, 10C, 10D has been
amplified by the amplification unit 16', the receiving unit 15'
receives wireless data transmitted from the pressure value
transmission unit 24. Note that the functions of the input unit 17,
the casting mold strength calculation unit 18, the casting mold
quality determination unit 19, the display unit 20, the
transmission unit 21, and the recording unit 22 are the same as the
functions of the casting mold quality evaluation device 12 for
wired data described earlier.
[0071] (Relationship Between Pressure Measured by Green Sand Mold
Molding Sensors and Casting Mold Strength of Molded Green Sand
Mold)
[0072] Next, there follows a description of the relationship
between the casting mold strength of a molded green sand mold and
the pressure value (peak pressure) that is applied to the parting
plane and measured by the green sand mold molding sensors. In order
to investigate the relationship between the foregoing, an
experiment was carried out by using a molding machine. FIG. 7 is a
schematic view representing a configuration of the experiment
carried out herein. Note that FIG. 7 represents: a positional
relationship between a plate and a sensor; an integrated
amplifier-recorder 25 that amplifies and records a signal from a
pressure sensor; and a computer 26 that is connected to the
integrated amplifier-recorder 25 and performs analysis such as
graphing sensor measurement values. The experiment was performed as
follows.
[0073] 1. Green sand mold molding sensors were installed (embedded)
in a plate made of aluminum. In this experiment, fluid pressure
sensors were used as the green sand mold molding sensors.
Installation locations were set at a total of three locations: in
the center of the plate and in opposing corners of the plate. Note
that for the sake of descriptions hereinafter, in the drawings, S1
and S2 are the two locations on the line between opposing corners
of the plate and close to the respective apexes, and S3 is the
central section of the plate. The reason for installing fluid
pressure sensors at the three locations S1, S2, and S3 is so as to
be able to acquire data in a large pressure range from one molding,
since the force acting on the plate during molding of a green sand
mold is high in the central section of the plate and low near the
metal frame due to frictional resistance between the metal frame
and the green sand. Further, since a fluid pressure sensor was also
disposed in the central section of the plate, the present
experiment was performed without attaching a model.
[0074] 2. The plate having the green sand mold molding sensors
installed therein was attached to a molding machine and a green
sand mold was molded. In addition, during a squeezing step, the
pressure applied to the parting plane was measured by the green
sand mold molding sensors at the three locations. Temporal changes
in the pressure value were measured and recorded in the integrated
amplifier-recorder 25. With respect to squeezing, pressure was
applied gradually up to a set pressure and was released when the
set pressure was reached.
[0075] 3. The casting mold strength of a green sand mold at
positions where the pressure was measured by the green sand mold
molding sensors was measured by a casting mold strength gauge and
the relationship between the pressure value and the casting mold
strength was investigated. Note that with respect to the strength
gauge that measured the casting mold strength, an invasive-type
casting mold strength gauge that is widely used in casting mold
factories to evaluate moldability of a green sand mold and that
measures the casting mold strength by introducing, approximately 10
mm into the casting mold, a needle having a tip diameter of
approximately 3 mm was used.
[0076] In addition, the abovementioned 2 and 3 were carried out on
a plurality of green sand molds and the data were collected. Table
1 summarizes these experimental conditions.
TABLE-US-00001 TABLE 1 SQUEEZING PRESSURE (MPa) 0.3~0. 7 GREEN SAND
FILLING METHOD FREE FALL CASTING MOLD STRENGTH INVASIVE-TYPE
CASTING MEASURING APPARATUS MOLD STRENGTH GAUGE BASE SAND OF GREEN
SAND SILICA SAND PROPERTIES OF GREEN SAND COMPACTABILITY (%) 33
.+-. 3 COMPRESSIVE STRENGTH (N/cm.sup.2) 22.1 PERMEABILITY 224
Experimental Results
[0077] FIG. 8 is a graph representing one example of results
obtained by recording, in the integrated amplifier-recorder 25,
temporal changes in the pressure of a green sand mold molding
sensor in the squeezing step and analyzing by the computer 26. Note
that FIG. 8 represents the case in which squeezing pressure was set
at 0.4 MPa and measurements were carried out at the three locations
S1, S2, and S3. As shown in FIG. 8, in this molding machine, the
peak pressure was reached in the squeezing step approximately two
seconds after squeezing commenced.
[0078] Further, upon confirming the relationship between the
position of the plate and the peak pressure, it was understood that
the pressure at the central section (S3) of the plate is the
highest and pressure becomes lower at places (S1, S2) away from the
central section. Due thereto, it was possible to confirm that near
the metal frame, the pressure propagated to the plate decreases due
to frictional resistance between the green sand and the metal
frame, which was mentioned earlier. Further, in one example of
these experimental results, the pressure at the central section
(S3) of the plate was almost the same as the set pressure (0.4
MPa).
[0079] FIG. 9 is a graph summarizing, upon having repeated the
abovementioned experiment, the relationship between the casting
mold strength and the peak pressure of the green sand mold molding
sensors which varies with the set squeezing pressure and the
filling state of the green sand. From this graph, a positive
correlation is seen in the relationship between the peak pressure
of the green sand mold molding sensors and the casting mold
strength and it is understood that it is possible to represent this
relationship with a straight line. In addition, from the straight
line, it is possible to determine the expression y=ax+b. Here, y is
the casting mold strength and x is the peak pressure. From these
results, it was understood that it is possible to evaluate the
casting mold strength (casting mold filling properties) from the
peak value of the pressure (squeezing pressure on the parting plane
of the green sand mold) of the green sand mold molding sensors.
[0080] The green sand mold molding sensors measure the pressure
when the filled green sand is tamped and the tamping force
(compression force) reaches the plate surface. The pressure
reaching this plate surface varies depending on the magnitude of
the tamping force, the density distribution of the filling of the
green sand before tamping (high pressure in high density portions,
low pressure in low density portions), the shape of the model
(pattern), and the characteristics of the green sand (low pressure
in high water content sand, high pressure in low water content
sand).
[0081] With respect to the evaluation of moldability by using the
green sand mold molding sensors, from the relationships [0082] high
peak pressure of green sand mold molding sensor=high filling
density of green sand=high casting mold strength, and [0083] low
peak pressure of green sand mold molding sensor=low filling density
of green sand=low casting mold strength, when the peak pressure of
the green sand mold molding sensor is low, there is a concern of
defects such as molten metal infiltration, sand drop/sand
inclusion, molten metal leakage, etc. When the peak pressure of the
green sand mold molding sensor is high, sliding resistance between
the model and the casting mold increases and there is a concern of
mold removal defects. As such, keeping the detected peak pressure
of the green sand mold molding sensors at a suitable level leads to
a reduction in defects.
[0084] The pressure conveyed to the green sand mold molding sensors
embedded in the plate varies due to the causes mentioned above and
therefore the embedding positions of the green sand mold molding
sensors must be places where it is possible to ascertain these
circumstances. Accordingly, if multiple green sand mold molding
sensors are installed, it is possible to detect flaws under more
conditions. However, due to space constraints and from an economic
perspective, this is not realistic and it is desirable to be able
to detect and evaluate pressure using a smaller number of
sensors.
[0085] As mentioned earlier, for the filling of green sand by the
casting mold molding device 1, a gravity drop method or a blowing
method that uses an airflow is employed. In the gravity drop method
that uses a louvered hopper, etc., mentioned earlier, a bias when
the green sand is loaded into the louvered hopper may become a bias
when loading into the casting mold molding space. Further, in the
blowing method, a bias may occur when loading into the casting mold
molding space due to circumstances such as the distance from the
blowing-in nozzle, sand blockage in the nozzle opening, etc. These
biases appear as biases in the pressure propagated to the plate 2
due to the subsequent tamping of the green sand. It is necessary to
dispose the green sand mold molding sensors by taking into
consideration the occurrence of such biases in initial filling
amounts.
[0086] In addition, in cases in which a difference in the
measurement value of a disposed green sand mold molding sensor is
outside a predetermined threshold value range, it can be determined
that the bias of the initial filling is large and it is possible to
take measures such as: improving the state in which casting mold
sand is loaded into the louvered hopper; adjusting blowing-in air
pressure or blowing-in time; or improving the state (blockage,
abrasion, etc.) of the blowing-in nozzle. Further, the flowability
of the green sand has an influence when the casting mold sand is
loaded into the louvered hopper, when loaded from the louvered
hopper to the casting mold molding space, or when blown-in by means
of blowing, etc. This flowability of the green sand varies
according to sand properties such as the water content of the green
sand and it is therefore possible to adjust the sand by using a
sand processing device such as a kneading machine that kneads green
sand to be supplied to the casting mold molding device 1.
[0087] Further, when green sand is tamped, the green sand is
compressed by a tamping force and a pressure is detected by the
green sand mold molding sensors embedded in the plate. The force
propagated to the plate is generally high in the (planar state)
central section of the casting mold and lower in a peripheral
section due to sliding resistance (or frictional resistance)
between the green sand and the casting frame side surface. In the
case of a rectangular casting mold, the force is lowest in corner
sections near the casting frame.
[0088] As such, in order to evaluate the force (pressure)
propagated to the plate due to the magnitude of the tamping force,
it is preferable to dispose green sand mold molding sensors near
the casting frame side surface, in particular, in the corner
sections. If a measurement value of a green sand mold molding
sensor disposed in this position does not reach a predetermined
lower limit threshold value, it can be judged that a sufficient
casting mold strength has not been reached and measures to increase
the tamping force can be taken. If the measurement value is higher
than an upper limit threshold value, it can be judged that the
casting mold strength is more than sufficient and measures to
decrease the tamping force can be undertaken.
[0089] In the present embodiment, considering the step for filling
the green sand and the step for tamping the green sand, the green
sand mold molding sensors 10A, 10B, 10C, 10D are embedded in the
four corners of the plate 2.
[0090] Note that the relationship between the peak value of the
pressure of the green sand mold molding sensors and the casting
mold strength is also the same when using another type of flask
molding machine or a flaskless molding machine. As such, this
relationship can also be applied in a casting mold molding device
of a second embodiment which is described later.
[0091] (Method for Calculating Casting Mold Strength)
[0092] Next, there follows a description of a method for
calculating the casting mold strength by using the casting mold
strength calculation unit 18. As mentioned above, it has been
ascertained that there is a correlative relationship between the
casting mold strength and the peak value of the pressure of the
green sand mold molding sensors. The casting mold strength
calculation unit 18 uses this relationship to calculate the casting
mold strength from the casting mold strength inputted into the
input unit 17 and the pressure value (peak pressure) measured by
the green sand mold molding sensors 10A, 10B, 10C, 10D.
[0093] Specifically, calculation of the casting mold strength by
the casting mold strength calculation unit 18 comprises two
steps.
[0094] Step 1
[0095] A predetermined number of green sand molds are molded in
advance and a pressure value (peak pressure) during squeezing is
measured by the green sand mold molding sensors 10A, 10B, 10C, 10D.
Furthermore, the casting mold strength at positions in each of the
molded green sand molds where the pressure was measured by the
green sand mold molding sensors 10A, 10B, 10C, 10D is measured and
inputted into the input unit 17 by a worker. In addition, a worker
determines the expression y=ax+b from the relationship between the
casting mold strength and the pressure value (peak pressure).
[0096] Note that in the present embodiment, on the basis of the
experimental results mentioned above, the green sand mold molding
sensors 10A, 10B, 10C, 10D are embedded in the four corners of the
plate 2. By measuring the pressure applied to the parting plane at
these four locations and determining a relationship with the
casting mold strength, it is possible to determine casting mold
quality by using a small number of green sand mold molding sensors
while taking into consideration variation in pressure on the plate
upper surface. Further, when making a predetermined number of
moldings, by varying the squeezing pressure, it is possible to
determine a relationship between the pressure applied to the
parting plane and the casting mold strength over a wider range.
[0097] FIG. 10 shows one example of a screen displayed on the
display unit 20. In the present example, first, a predetermined
green sand mold is molded and seven pressure values (peak
pressures) measured by the green sand mold molding sensors 10A, 10B
at that time are displayed on the screen. Note that it is also
possible to switch to a screen which displays seven pressure values
(peak pressures) measured by the green sand mold molding sensors
10C, 10D, and that furthermore, one screen may be configured so
that seven pressure values (peak values) measured by the green sand
mold molding sensors 10A, 10B, 10C, 10D are displayed on the
screen.
[0098] In addition, the casting mold strength at positions in each
of the molded green sand molds where the green sand mold molding
sensors 10A, 10B, 10C, 10D were disposed is inputted as an input
value by a worker. Here, "Peak pressure A" and "Casting mold
strength A" shown in FIG. 10 are, respectively, the peak pressure
value of the green sand mold molding sensor 10A and the casting
mold strength at the position of the green sand mold molding sensor
10A. Further, "Peak pressure B" and "Casting mold strength B" in
the FIG. 10 are, respectively, the peak pressure value of the green
sand mold molding sensor 10B and the casting mold strength at the
position of the green sand mold molding sensor 10B; "Peak pressure
C" and "Casting mold strength C" displayed on the switched screen
are, respectively, the peak pressure value of the green sand mold
molding sensor 10C and the casting mold strength at the position of
the green sand mold molding sensor 10C; and "Peak pressure D" and
"Casting mold strength D" displayed on the switched screen are,
respectively, the peak pressure value of the green sand mold
molding sensor 10D and the casting mold strength at the position of
the green sand mold molding sensor 10D.
[0099] The casting mold strength calculation unit 18 plots the
casting mold strength and the peak value of the pressure of the
green sand mold molding sensors on a graph (in the present example,
7.times.4=28 places). In addition, when a worker inputs
predetermined values for the slope "a" and the intersect "b" of the
expression, a straight line y=ax+b is displayed. While confirming
the plots, a worker changes numerical values of the slope "a" and
the intersect "b", as appropriate, and upon determining that there
is a linear correlation among the plots, determines a final
expression y=ax+b. Note that if there are no problems in terms of
casting mold strength with a green sand mold for which the casting
mold strength has been measured by a worker, it is possible for
manufacturing to proceed as-is by carrying out subsequent steps
(core setting step, molten metal pouring step, etc.). Note also
that in the above description, a worker inputted the slope "a" and
the intersect "b" of the expression, but these may also be
determined by using a computer or a PLC and performing a linear
regression by a least-squares method, etc.
[0100] Step 2
[0101] After determining the expression y=ax+b, molding of the
green sand mold commences. After commencing, the expression y=ax+b
is used to automatically calculate the casting mold strength at the
positions of the green sand mold molding sensors 10A, 10B, 10C, 10D
from the pressure value (peak pressure) measured by the green sand
mold molding sensors 10A, 10B, 10C, 10D. Due thereto, there is no
need for a worker to measure the casting mold strength
separately.
[0102] Note that in the present example, the casting mold strength
is measured using a casting mold strength gauge and the number of
peak pressures and casting mold strengths displayed on the screen
is seven each for A and B. However, this may be changed, as
appropriate, according to the specifications of the casting mold
molding device 1, specifications such as shape and size of the
green sand mold to be molded, etc., or the specifications of the
green sand.
[0103] (Method for Determining Casting Mold Quality)
[0104] Next, there follows a description of a method for
determining casting mold quality by using the casting mold quality
determination unit 19. The casting mold quality determination unit
19 determines the quality of a green sand mold from the threshold
value of the casting mold strength inputted into the input unit 17
and the casting mold strength calculated by the casting mold
strength calculation unit 18.
[0105] Specifically, determination of the casting mold quality by
the casting mold quality determination unit 19 comprises two
steps.
[0106] Step 1
[0107] First, a worker inputs a threshold value of the casting mold
strength of a green sand mold to be molded. FIG. 11 shows one
example of a screen displayed on the display unit 20. In the
present example, specific threshold values inputted by a worker are
displayed. Here, "Sensor A strength normal range" in FIG. 11
indicates the lower limit value and the upper limit value of the
casting mold strength at the position of the green sand mold
molding sensor 10A; "Sensor B strength normal range" in FIG. 11
indicates the lower limit value and the upper limit value of the
casting mold strength at the position of the green sand mold
molding sensor 10B; "Sensor C strength normal range" in FIG. 11
indicates the lower limit value and the upper limit value of the
casting mold strength at the position of the green sand mold
molding sensor 10C; and "Sensor D strength normal range" in FIG. 11
indicates the lower limit value and the upper limit value of the
casting mold strength at the position of the green sand mold
molding sensor 10D. Further, "Casting mold strength difference
(Max.-Min.) abnormality value" shown in FIG. 11 indicates a
threshold value wherein the difference between the maximum and
minimum values of the casting mold strength determined from the
pressure value of the green sand mold molding sensors 10A, 10B,
10C, 10D is set as an abnormality value.
[0108] In the present example, the lower limit value of the casting
mold strength at the position of the green sand mold molding
sensors 10A, 10B, 10C, 10D is set as 10.0 (N/cm2), the upper limit
value of the same is set as 20.0 (N/cm2), and the threshold value
wherein the difference between the maximum value and the minimum
value of the casting mold strength at the position of the green
sand mold molding sensors 10A, 10B, 10C, 10D is set as an
abnormality value is set as 5.0 (N/cm2).
[0109] Step 2
[0110] After the expression y=ax+b is determined by the casting
mold strength calculation unit 18 and the threshold value of the
casting mold strength is inputted, molding of the green sand mold
commences. After commencing, the casting mold strength at the
position of the green sand mold molding sensors 10A, 10B, 10C, 10D
is automatically calculated from the pressure value (peak pressure)
measured by the green sand mold molding sensors 10A, 10B, 10C, 10D.
In addition, the quality of a green sand mold is determined from
the inputted threshold value of the casting mold strength and the
calculated casting mold strength. Here, determination of the
quality of a green sand mold is performed as follows. In the
present example, the threshold values of the casting mold strength
A, the casting mold strength B, the casting mold strength C, and
the casting mold strength D are each set as 10.0 (N/cm2) or more
and 20.0 (N/cm2) or less, and the abnormality threshold value of
the difference between the maximum value and the minimum value of
the casting mold strength at the positions of the green sand mold
molding sensors 10A, 10B, 10C, 10D is set as 5.0 (N/cm2) or
more.
[0111] Accordingly, in the case in which the casting mold strength
at the position of the green sand mold molding sensor 10A is 13.0
(N/cm2), the casting mold strength at the position of the green
sand mold molding sensor 10B is 12.0 (N/cm2), the casting mold
strength at the position of the green sand mold molding sensor 10C
is 16.0 (N/cm2), and the casting mold strength at the position of
the green sand mold molding sensor 10D is 14.0 (N/cm2), the casting
mold strength A, the casting mold strength B, the casting mold
strength C, and the casting mold strength D are all within the
threshold values. Furthermore, the maximum value of the casting
mold strengths A, B, C, D is 16.0 (N/cm2), the minimum value is
12.0 (N/cm2), and the difference between the maximum and the
minimum is 4.0 (N/cm2), which is within the range, and therefore
the casting mold quality determination unit 19 determines that the
casting mold quality is OK.
[0112] In contrast thereto, in the case in which the casting mold
strength at the position of the green sand mold molding sensor 10A
is 11.0 (N/cm2), the casting mold strength at the position of the
green sand mold molding sensor 10B is 17.0 (N/cm2), the casting
mold strength at the position of the green sand mold molding sensor
10C is 12.0 (N/cm2), and the casting mold strength at the position
of the green sand mold molding sensor 10D is 16.0 (N/cm2), the
casting mold strength A, the casting mold strength B, the casting
mold strength C, and the casting mold strength D are all within the
threshold values. However, the maximum value of the casting mold
strengths A, B, C, D is 17.0 (N/cm2), the minimum value is 11.0
(N/cm2), and the difference between the maximum and the minimum is
6.0 (N/cm2), which is not within the range, and therefore the
casting mold quality determination unit 19 determines that the
casting mold quality is faulty.
[0113] FIG. 12 shows one example of a screen displayed on the
display unit 20. Here, "Peak pressure A", "Peak pressure B", "Peak
pressure C", and "Peak pressure D" in FIG. 12 indicate,
respectively, the peak pressure value of the green sand mold
molding sensor 10A, the peak pressure value of the green sand mold
molding sensor 10B, the peak pressure value of the green sand mold
molding sensor 10C, and the peak pressure value of the green sand
mold molding sensor 10D. Further, "Casting mold strength A",
"Casting mold strength B", "Casting mold strength C", and "Casting
mold strength D" indicate, respectively, the casting mold strength
at the position of the green sand mold molding sensor 10A
calculated by the casting mold strength calculation unit 18, the
casting mold strength at the position of the green sand mold
molding sensor 10B calculated by the casting mold strength
calculation unit 18, the casting mold strength at the position of
the green sand mold molding sensor 10C calculated by the casting
mold strength calculation unit 18, and the casting mold strength at
the position of the green sand mold molding sensor 10D calculated
by the casting mold strength calculation unit 18.
[0114] Furthermore, "Casting mold strength difference (Max.-Min.)"
in FIG. 12 indicates the difference between the maximum value and
the minimum value of the casting mold strengths A, B, C, D.
Further, "Determination" in FIG. 12 indicates a determination
result for the casting mold quality by the casting mold quality
determination unit 19.
[0115] Note that on the screen of the display unit 20 in FIG. 12, a
poor numerical value is displayed by shading or coloring the inside
of a cell, and OK (normal) and FT (faulty) can be understood at a
glance.
[0116] Note that the threshold values and the difference between
the maximum value and the minimum value set for the casting mold
strength A, the casting mold strength B, the casting mold strength
C, and the casting mold strength D are determined, as appropriate,
in accordance with the specifications of the casting mold molding
device 1, specifications such as shape, size, etc., of the green
sand mold to be molded, the site of the green sand mold, or the
specifications of the green sand, etc. In addition, these values
are associated with a model number.
[0117] In the casting mold molding device 1 of the present
embodiment, even if the specifications such as shape, size, etc.,
of a green sand mold to be molded change, in each case, it is
possible for the casting mold strength calculation unit 18 to
calculate the casting mold strength and for the casting mold
quality determination unit 19 to determine the quality of the
molded green sand mold from the calculated casting mold
strength.
[0118] (Method for Evaluating Casting Mold Quality Using Casting
Mold Molding Device)
[0119] Next, there follows a description of a method for evaluating
casting mold quality (method for molding a green sand mold) using
the casting mold molding device 1. FIG. 13 shows steps in a method
for evaluating casting mold quality (method for molding a green
sand mold) using the casting mold molding device 1 according to the
first embodiment. Note that in FIG. 13, a louvered hopper 27 is
coupled to the squeeze head 7 of the casting mold molding device 1
shown in FIG. 1. The louvered hopper 27 has a structure wherein a
predetermined amount of green sand is loaded therein from a green
sand transportation device (not shown) and, after having been
briefly retained, louvers 28 at a lower portion of the louvered
hopper 27 open and the green sand is loaded into the casting mold
molding space.
[0120] Molding of a green sand mold by the casting mold molding
device 1 follows the procedure described below.
[0121] 1. When molding is commenced, a table 9 rises and thereby a
state shown in FIG. 13(a) is achieved. At this time, a
predetermined amount of green sand is loaded into the louvered
hopper 27 from the green sand transportation device (not
shown).
[0122] 2. Then, as shown in FIG. 13(b), the louvers 28 at a lower
portion of the louvered hopper 27 open and the green sand inside
the louvered hopper 27 is loaded into the casting mold molding
space defined by the plate 2, the metal frame 5 and the filling
frame 6.
[0123] 3. Then, as shown in FIG. 13(c), the coupled squeeze head 7
and louvered hopper 27 move, the squeeze board 8 is arranged
directly above the casting mold molding space, and next, the table
9 rises and thereby the green sand inside the casting mold molding
space is squeezed (compressed). At this time, the green sand mold
molding sensors 10A, 10B, 10C, 10D measure the pressure value (peak
pressure) at the parting plane. Note that the casting mold is
molded in the present step. At this time, the green sand mold
molding sensors 10A, 10B, 10C, 10D are between the wall of the
metal frame 5 and the model 3 in the plate 2.
[0124] 4. The pressure value (peak pressure) at the parting plane
is transmitted to the casting mold quality evaluation device 12 and
the quality of the green sand mold that has just been molded is
evaluated.
[0125] Quality evaluation by the casting mold quality evaluation
device 12 is performed after the expression y=ax+b, which
represents the relationship between casting mold strength and the
peak value of the pressure of the green sand mold molding sensors,
has been determined in advance. In addition, a green sand mold
determined to be OK by the casting mold quality evaluation device
12 flows, as-is, along the line and subsequent steps (molten metal
pouring, etc.) are carried out. Meanwhile, a green sand mold
determined to be faulty by the casting mold quality evaluation
device 12 flows, as-is, along the line, but subsequent steps
(molten metal pouring, etc.) are not carried out. The green sand
mold skips these steps and, as a casting mold to be discarded, is
shaken out from the mold in the same way as a green sand mold
having a casting mold quality evaluation determined as being OK.
Thus, it is possible to make a determination of "good" or "poor"
with respect to the quality of a molded casting mold for each
frame, which can therefore lead to a casting mold quality assurance
for each frame. Further, it is possible to judge a defect at the
time of molding a green sand mold and therefore it is possible to
reduce defects in castings produced. Furthermore, it is possible to
omit unnecessary work and therefore it is possible to reduce
production costs.
[0126] 5. Then, in the casting mold molding device 1, the table 9
lowers, the filling frame 6 separates from the metal frame 5 upper
surface, and when the table lowers further, the metal frame 5
containing the green sand mold is placed on a roller conveyor
connected to subsequent steps such as core-setting, molten metal
pouring, etc., the model 3 is removed from the green sand mold, and
the lowering of the table 9 stops. Next, the metal frame 5
containing the green sand mold is conveyed on the roller conveyor
to a subsequent step and the metal frame 5 is loaded into the
casting mold molding device 1 in preparation for the next molding.
Note that when the lowering of the table 9 commences, a
predetermined amount of green sand is supplied to the louvered
hopper 27 with the louvers 28 closed.
[0127] 6. When the metal frame 5 has been loaded in preparation for
the next molding and the supplying of green sand to the louvered
hopper 27 has been completed, the coupled squeeze head 7 and
louvered hopper 27 move, the table 9 rises in a state in which the
louvered hopper 27 is arranged directly above the casting mold
molding space, and molding of the next green sand mold
commences.
[0128] In addition, pressure value data, casting mold strength data
associated with pressure values, casting mold strength calculation
results, and casting mold quality determination results, etc.,
which are produced during the molding step, are all recorded in the
recording unit 22 of the casting mold quality evaluation device 12.
Therefore, it is possible to use these numerical values to monitor
the operational state of the casting mold molding device 1 and
these numerical values are useful in quality control, maintenance,
and troubleshooting of the casting mold molding device 1.
Furthermore, using these numerical values can lead to early
detection of defect causes such as: sand spillage, burn-in of a
casting, and mold drop which occur due to filling defects; and
swelling of a green sand mold due to molten metal pressure after
pouring.
[0129] Furthermore, the data recorded in the recording unit 22 are
recorded for each model attached to the plate 2. Therefore, it is
possible to compare and examine a state, such as a defect in a
green sand mold, with pressure value data, and setting of a more
accurate threshold value becomes possible.
[0130] Further, in the present embodiment, a worker determines the
expression y=ax+b by considering the slope "a" and the intercept
"b" of the expression from the casting mold strengths and peak
values of the pressure of the green sand mold molding sensors
plotted on a graph. However, it is also possible to configure so
that the casting mold strength calculation unit 18 automatically
calculates the expression y=ax+b from the relationship between the
casting mold strength and the peak value of the pressure of the
green sand mold molding sensors by using a computer or a PLC and
performing a linear regression by a least-squares method, etc.
[0131] Further, in the present embodiment, in the case that a
molded green sand mold is determined to be a defect, a worker
clarifies that the green sand mold in question is a defect.
However, it is also possible to configure so that a determination
result is automatically communicated to casting mold equipment of a
subsequent step (molten metal pouring, etc.). In that case, at a
subsequent step, the casting mold equipment automatically
recognizes that the green sand mold in question is a defect, omits
(skips) the step, and finally the green sand mold in question is
shaken out from the mold.
[0132] Further, in the present embodiment, the green sand mold
molding sensors 10A, 10B, 10C, 10D are embedded in the four corners
of the plate 2. However, even if the number of green sand mold
molding sensors embedded in the plate 2 is smaller, it is possible
to calculate the relationship between the casting mold strength and
the peak value of the pressure of the green sand mold molding
sensors. In that case, accuracy is slightly lower in comparison
with the case in which green sand mold molding sensors are embedded
in four locations, but it is possible to curb costs.
[0133] In that case, it is also possible to embed green sand mold
molding sensors at two locations on a line between opposing corners
shown in FIG. 2: positions 10A and 10B; or 10C and 10D. FIGS. 14
and 15 show other examples of the plate 2 having green sand mold
molding sensors 10A, 10B embedded therein. In FIG. 14, the two
green sand mold molding sensors 10A, 10B are embedded near the
central section of the long sides of the plate 2. In FIG. 15, the
two green sand mold molding sensors 10A, 10B are embedded near the
central section of the short sides of the plate 2.
[0134] (Mode of Plate)
[0135] FIG. 16 shows a different mode of the plate 2. FIG. 16(a)
shows a plate 2a and a plate 2b which are placed on the carrier 4.
In other words, the plate 2 is divided into a central plate 2a and
a peripheral plate 2b. The central plate 2a and the peripheral
plate 2b are fixed by bolts (not shown).
[0136] The model 3 is attached to an upper surface of the central
plate 2a. Further, the green sand mold molding sensors 10A, 10B,
10C, 10D are embedded in the peripheral plate 2b. The shapes of the
central plate 2a and the peripheral plate 2b are configured while
taking into consideration the shape of the model for molding in the
casting mold molding device 1 and the positions of the green sand
mold molding sensors mentioned above. The shapes of alignment
sections of the central plate 2a and the peripheral plate 2b are
configured so as to share a common shape, and when a model for
molding in the casting mold molding device 1 is to be changed, the
central plate 2a which has the model 3 attached thereto only needs
to be replaced.
[0137] FIG. 16(b) shows a state wherein the central plate 2a is
detached. By loosening the bolts (not shown) and removing only the
central plate 2a, which has the model 3 attached thereto, and
attaching a central plate having a different model attached
thereto, it is possible to easily exchange models without affecting
the green sand mold molding sensors.
[0138] Thus, according to the green sand mold molding sensor of the
first embodiment, in order to determine the quality of a molded
casting (casting mold strength), it is possible to measure, during
molding of a green sand mold, a pressure value (peak pressure)
applied to a parting plane which is a joining section between the
plate 2 and the upper mold (or lower mold) comprising green sand
mold sand formed inside the casting mold molding space.
Second Embodiment
[0139] Next, there follows a description of a second embodiment of
the green sand mold molding sensor and the method for evaluating
green sand mold moldability according to the present invention.
Note that in the second embodiment described below, for
configurations common with the first embodiment, the same reference
signs are used in the drawings and descriptions thereof are
omitted. In the second embodiment, a flaskless molding machine,
rather than a flask molding machine, is used.
[0140] The second embodiment will be described with reference to
the attached drawings. FIG. 17 represents a schematic of a
structure of the casting mold molding device using green sand mold
molding sensors according to the second embodiment and FIG. 18
represents a configuration of a portion of the casting mold molding
device, wherein the portion evaluates casting mold quality. The
casting mold molding device according to the present embodiment is
a flaskless molding machine in which, after a green sand mold is
molded, the green sand mold is removed from a casting frame.
[0141] A casting mold molding device 29 comprises the plate 2
having the model 3 attached to the upper and lower surfaces
thereof, a shuttle dolly 30, a cope (metal frame) 31, a drag (metal
frame) 32, an upper squeeze board 33, a lower squeeze board 34, the
green sand mold molding sensors 10A, 10B, 10C, 10D embedded in the
upper surface of the plate 2, green sand mold molding sensors 10E,
10F, 10G, 10H embedded in the lower surface of the plate 2, the
wiring 11, and the casting mold quality evaluation device 12. Note
that FIG. 18 represents the plate 2, the model 3 attached to the
upper surface thereof, the shuttle dolly 30, and the green sand
mold molding sensors 10A, 10B, 10C, 10D as seen when viewed from
the upper side of the plate 2 of the casting mold molding device
29. Note also that the green sand mold molding sensors 10E, 10F,
10G, 10H are embedded in the lower surface of the plate 2 and are
therefore not shown in FIG. 18.
[0142] The plate 2 has attached to the upper and lower surfaces
thereof a model 3 for molding a shape of a casting in a green sand
mold and is rectangular. The shuttle dolly 30 has the plate 2
placed thereon and makes round trips between the inside and the
outside of the casting mold molding device 29 in accordance with
the step. The cope 31 has green sand filled therein in order to
mold an upper mold of the green sand mold. In other words, the
casting mold molding space surrounded by the cope 31, the upper
squeeze board 33, and the plate 2 is filled with green sand. The
drag 32 has green sand filled therein in order to mold a lower mold
of the green sand mold. In other words, the casting mold molding
space surrounded by the drag 32, the lower squeeze board 34, and
the plate 2 is filled with green sand. The plate 2 is a member that
constitutes a part of a boundary of the molding space defined by
the cope 31 or the drag 32 during green sand mold molding by the
casting mold molding device 29.
[0143] For the filling of green sand by the casting mold molding
device 29, a blowing method that uses an airflow is employed. The
blowing method is a method for filling green sand by blowing in
green sand to the upper and lower surfaces of the plate 2 from
green sand blowing-in ports 35, 35 of the cope 31 and drag 32.
[0144] The upper squeeze board 33 and the lower squeeze board 34
act via a cylinder (not shown), and the upper and lower green sand
molds are molded simultaneously by tamping and compressing the
green sand filled in the cope 31 and the green sand filled in the
drag 32.
[0145] (Green Sand Mold Molding Sensor)
[0146] The green sand mold molding sensors 10A, 10B, 10C, 10D and
10E, 10F, 10G, 10H measure, during molding of a green sand mold, a
pressure value (peak pressure) applied to a parting plane which is
a joining section of the plate 2 between the upper mold comprising
green sand formed inside the cope 31 and the lower mold comprising
green sand formed inside the drag 32. The green sand mold molding
sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G, 10H are pressure
sensors. In the present embodiment, the green sand mold molding
sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G, 10H are embedded in
the four corners of the upper and lower surfaces of the plate 2.
The reason that the green sand mold molding sensors 10A, 10B, 10C,
10D, and 10E, 10F, 10G, 10H are embedded in such a way is the same
as the reason described in the first embodiment.
[0147] In addition, the green sand mold molding sensors 10A, 10B,
10C, 10D, and 10E, 10F, 10G, 10H have a pressure-receiving surface
for measuring pressure that is exposed in the upper surface or
lower surface of the plate 2 and measures the pressure value (peak
pressure) applied to the parting plane above and below the plate 2.
At this time, it is desirable for the pressure-receiving surface of
the green sand mold molding sensors 10A, 10B, 10C, 10D and 10E,
10F, 10G, 10H and the upper and lower surfaces of the plate 2 to be
in a flush state with no differences in level therebetween. Due
thereto, it is possible to measure the precise pressure.
[0148] The wiring 11 connects the casting mold quality evaluation
device 12 to the green sand mold molding sensors 10A, 10B, 10C,
10D, and 10E, 10F, 10G, 10H. In the present embodiment, the green
sand mold molding sensors 10A, 10B, 10C, 10D, and 10E, 10F, 10G,
10H, and the casting mold quality evaluation device 12 are
connected by wire via the wiring 11 but may also be connected
wirelessly. For example, it is possible to use wireless
communication such as a wireless LAN or Bluetooth, etc., to
transmit the pressure value (pressure value data) detected by the
green sand mold molding sensors 10A, 10B, 10C, 10D, and 10E, 10F,
10G, 10H to the casting mold quality evaluation device 12.
[0149] The casting mold quality evaluation device 12 evaluates the
quality of the green sand mold molded by the casting mold molding
device 29 from the pressure value (pressure value data) measured by
the green sand mold molding sensors 10A, 10B, 10C, 10D, and 10E,
10F, 10G, 10H. The casting mold quality evaluation device 12
comprises a receiving unit 15, an amplification unit 16, an input
unit 17, a casting mold strength calculation unit 18, a casting
mold quality determination unit 19, a display unit 20, a
transmission unit 21, and a recording unit 22.
[0150] The receiving unit 15 receives the pressure value (pressure
value data) measured by the green sand mold molding sensors 10A,
10B, 10C, 10D and 10E, 10F, 10G, 10H. The amplification unit 16
amplifies the signal amount of the received pressure value
(pressure value data). The input unit 17 inputs: the casting mold
strength of a molded green sand mold, measured by a casting mold
strength gauge; values of a slope "a" and an intercept "b" of the
expression y=ax+b; and a threshold value of the casting mold
strength of a green sand mold to be molded, etc.
[0151] From the casting mold strength inputted into the input unit
17 and the pressure value (peak pressure) measured by the green
sand mold molding sensors 10A, 10B, 10C, 10D, and 10E, 10F, 10G,
10H, the casting mold strength calculation unit 18 uses the
relational expression between the casting mold strength and the
measurement values to calculate the casting molding strength for
each pressure value (peak pressure) measured by the green sand mold
molding sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G, 10H.
[0152] The casting mold quality determination unit 19 determines
the quality of a molded green sand mold from the threshold value of
the casting mold strength inputted into the input unit 17 and the
calculated casting mold strength. The display unit 20 displays on a
screen: the pressure value (peak pressure) measured by the green
sand mold molding sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G,
10H; values of the slope "a" and the intercept "b" of the
relational expression y=ax+b between the casting mold strength
inputted by a worker using the input unit 17 and the pressure value
(peak pressure); the threshold value of the casting mold strength
of a green sand mold to be molded that was inputted by a worker;
the casting mold strength calculation result; and the casting mold
quality determination result, etc.
[0153] The transmission unit 21 transmits fault-determination data
to the Patlite 23, etc. The recording unit 22 records pressure
value data, casting mold strength data associated with pressure
values, casting mold strength calculation results, and casting mold
quality determination results, etc.
[0154] (Method for Evaluating Casting Mold Quality Using Casting
Mold Molding Device)
[0155] Next, there follows a description of a method for evaluating
casting mold quality (method for molding a green sand mold) using
the casting mold molding device 29. FIG. 19 shows steps in a method
for evaluating casting mold quality (method for molding a green
sand mold) using the casting mold molding device 29 according to
the second embodiment. Note that in FIG. 19, a sand tank 36 is
adjacent to the casting mold molding device 29 shown in FIG. 17. A
predetermined amount of green sand is loaded into the sand tank 36
from the green sand transportation device (not shown) and, after
having been briefly retained, a loading hole is closed and when
compressed air is supplied inside the sand tank 36, green sand is
filled by being blown into the upper and lower casting mold molding
spaces via green sand blowing-in ports 35, 35 in the cope 31 and
the drag 32.
[0156] Molding of a green sand mold by the casting mold molding
device 29 follows the procedure described below.
[0157] 1. When molding commences, from the state shown in FIG.
19(a), the shuttle dolly 30 having placed thereon the plate 2,
which has the models 3, 3 attached thereto and the green sand mold
molding sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G, 10H embedded
therein, moves between the cope 31 and the drag 32.
[0158] 2. Next, the lower squeeze board 34 and the drag 32 rise,
lift the plate 2 from the shuttle dolly 30, and when the state
shown in FIG. 19(b) is set, compressed air is supplied to the sand
tank 36 and green sand is filled by being blown into the upper and
lower casting mold molding spaces via the green sand blowing-in
ports 35, 35 in the cope 31 and the drag 32.
[0159] 3. Next, due to the action of a cylinder (not shown), the
upper and lower squeeze boards 33, 34 squeeze (compress) the green
sand inside the cope 31 and the drag 32 and the state shown in FIG.
19(c) is achieved. At this time, the green sand mold molding
sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G, 10H measure the
pressure value (peak pressure) at the parting plane. Note that
green sand molds are molded in the present step. At this time, the
green sand mold molding sensors 10A, 10B, 10C, 10D and 10E, 10F,
10G, 10H are between the model 3 and the walls of the cope 31 and
the drag 32 of the plate 2. At this time, the measured pressure
value (peak pressure) is transmitted to the casting mold quality
evaluation device 12 and the quality of the green sand mold that
has just been molded is evaluated.
[0160] Quality evaluation by the casting mold quality evaluation
device 12 is performed after the expression y=ax+b, which
represents the relationship between casting mold strength and the
peak value of the pressure of the green sand mold molding sensors,
has been determined in advance. In addition, a green sand mold
determined to be OK by the casting mold quality evaluation device
12 flows, as-is, along the line and subsequent steps (molten metal
pouring, etc.) are carried out. Meanwhile, a green sand mold
determined to be faulty by the casting mold quality evaluation
device 12 flows, as-is, along the line, but subsequent steps
(molten metal pouring, etc.) are not carried out. The green sand
mold skips these steps and, as a casting mold to be discarded, is
shaken out from the mold in the same way as a green sand mold for
which the casting mold quality is determined to be OK.
[0161] 4. Next, the lower squeeze board 34 and the drag 32 lower
and when the plate 2 is placed on the shuttle dolly 30, a state in
which the models 3, 3, are removed from the upper and lower green
sand molds is reached. Then, the shuttle dolly 30 moves to the
position shown in FIG. 19(a) and when the lower squeeze board 34
and the drag 32 rise again, mold alignment of the upper and lower
green sand molds is carried out by aligning the cope 31 and the
drag 32. At this time, the upper and lower green sand molds are in
a state of being sandwiched by the upper squeeze board 33 and the
lower squeeze board 34. From this state, when the upper squeeze
board 33 and the lower squeeze board 34 lower, the aligned upper
and lower green sand molds are lowered and removed from the cope 31
and the drag 32 to reach the state shown in FIG. 19(d).
[0162] 5. The aligned upper and lower green sand molds are
transported from the casting mold molding device 29 to a line of
the next step.
[0163] In addition, pressure value data, casting mold strength data
associated with pressure values, casting mold strength calculation
results, and casting mold quality determination results, etc.,
which are produced during the molding step, are all recorded in the
recording unit 22 of the casting mold quality evaluation device 12.
Therefore, it is possible to use these numerical values to monitor
the operational state of the casting mold molding device 29 and
these numerical values are useful in quality control, maintenance,
and troubleshooting of the casting mold molding device 29.
Furthermore, using these numerical values can lead to early
detection of defect causes such as: sand spillage, burn-in of a
casting, and mold drop which occur due to filling defects; and
swelling of a green sand mold due to molten metal pressure after
pouring.
[0164] Further, in the present embodiment, the green sand mold
molding sensors 10A, 10B, 10C, 10D and 10E, 10F, 10G, 10H are
embedded in the four corners of the upper and lower surfaces of the
plate 2 near the cope 31 and the drag 32. However, even if the
number of green sand mold molding sensors embedded in the plate 2
is small, it is possible to calculate the relationship between the
casting mold strength and the peak value of the pressure of the
green sand mold molding sensors. In that case, accuracy is slightly
lower in comparison with the case in which green sand mold molding
sensors are embedded in four locations, but it is possible to curb
costs.
[0165] In that case, it is also possible to set two locations 10A,
10B or 10C, 10D on a line between opposing corners of the upper
surface of the plate 2 shown in FIG. 18 or to set two locations
10E, 10F or 10G, 10H on a line between opposing corners of the
lower surface of the plate 2. FIGS. 20 and 21 show other examples
wherein the plate 2 upper surface has green sand mold molding
sensors 10A, 10B embedded therein. In FIG. 20, the two green sand
mold molding sensors 10A, 10B are embedded near the central section
of the long sides of the plate 2. In FIG. 21, the two green sand
mold molding sensors 10A, 10B are embedded near the central section
of the short sides of the plate 2. It is possible to dispose the
molding sensors 10E, 10F in the same state in the lower surface of
the plate 2. Due to the arrangement of these molding sensors, it is
possible to ascertain a bias in the filling amount, etc., between
right and left of the green sand blowing-in ports 35, 35, or in the
proximity or distance of the green sand blowing-in ports 35,
35.
[0166] (Mode of Plate)
[0167] FIG. 22 shows a different mode of the plate 2 wherein the
model 3 is attached to the upper and lower surfaces thereof. FIG.
22(a) shows a plate 2a and a plate 2b which are placed on the
shuttle dolly 30. In other words, the plate 2 is divided into a
central plate 2a and a peripheral plate 2b. The central plate 2a
and the peripheral plate 2b are fixed by bolts (not shown).
[0168] The model 3 is attached to upper and lower surfaces of the
central plate 2a. Further, the green sand mold molding sensors 10A,
10B, 10C, 10D are embedded in the upper surface of the peripheral
plate 2b and the green sand mold molding sensors 10E, 10F, 10G, 10H
are embedded in the lower surface of the peripheral plate 2b. The
shapes of the central plate 2a and the peripheral plate 2b are
configured while taking into consideration the shape of the model
for molding in the casting mold molding device 29 and the positions
of the green sand mold molding sensors mentioned above. The shapes
of the alignment sections of the central plate 2a and the
peripheral plate 2b are configured so as to share a common shape,
and when a model for molding in the casting mold molding device 29
is to be changed, the central plate 2a which has the models 3, 3
attached thereto only needs to be replaced.
[0169] FIG. 22(b) shows a state wherein the central plate 2a is
detached. By loosening the bolts (not shown) and removing only the
central plate 2a, which has the models attached thereto, and
attaching a central plate having a different model attached
thereto, it is possible to easily exchange models without affecting
the green sand mold molding sensors.
[0170] Thus, according to the green sand mold molding sensor of the
second embodiment, in order to determine the quality of a molded
casting (casting mold strength), it is possible to measure, during
molding of a green sand mold, a pressure value (peak pressure)
applied to a parting plane which is a joining section between the
upper mold comprising green sand mold sand formed inside the cope 4
and the lower mold comprising green sand mold sand formed inside
the drag 5.
[0171] (Modifications)
[0172] In the first and second embodiments, after determining the
relationship between the casting mold strength and the pressure
value (peak pressure) from the measured casting mold strength and
the pressure value (peak pressure) measured by the green sand mold
molding sensors 10A, 10B, 10C, 10D (and 10E, 10F, 10G, 10H), the
casting mold quality evaluation device 12 separately calculates the
casting mold strength from the pressure value (peak pressure)
measured by the green sand mold molding sensors 10A, 10B, 10C, 10D
(and 10E, 10F, 10G, 10H). In addition, the quality of a molded
green sand mold is determined from the pre-set threshold value of
the casting mold strength and the calculated casting mold
strength.
[0173] Additionally, by feeding back results determined by the
casting mold quality evaluation device 12 to a kneading machine, it
is possible to accurately control the amount of water injected into
the kneading machine. For example, if the pressure value (peak
pressure) measured by the green sand mold molding sensors 10A, 10B,
10C, 10D (and 10E, 10F, 10G, 10H) is extremely low and as a result
thereof the casting mold strength is extremely low, the casting
mold quality evaluation device 12 determines that the reason
therefor is because sand was not filled evenly inside the casting
mold and that the cause thereof is that the CB value of the green
sand is high, and by providing an instruction to the kneading
machine to reduce the amount of water injected, it is possible to
resolve the filling defect of the green sand.
[0174] Furthermore, by feeding back, to the kneading machine,
results determined by the casting mold quality evaluation device 12
and results obtained by a green sand automatic measurement system,
or the like, measuring and evaluating the compressive strength of
the green sand, it is also possible to control the amount of
additives, water, etc., loaded into the kneading machine. For
example, it is possible to perform an evaluation of the
flowability, etc., of the green sand from: properties of the green
sand measured by the green sand automatic measurement system such
as the compressive strength, permeability, compactability value,
water content value, etc. of the green sand; the pressure value
(peak pressure) measured by the green sand mold molding sensors
10A, 10B, 10C, 10D (and 10E, 10F, 10G, 10H); and the distribution
thereof. Further, by changing the amount of additives, water
content, etc., loaded during kneading, it is possible to resolve
casting mold defects.
[0175] Furthermore, in the first and second embodiments, the
casting mold quality evaluation device 12 converts the pressure
value (peak pressure) measured by the green sand mold molding
sensors 10A, 10B, 10C, 10D (and 10E, 10F, 10G, 10H) into a casting
mold strength and determines the quality of molded green sand molds
based on the converted casting mold strength and the measured
casting mold strength. However, since it has been ascertained that
there is a correlative relationship between the pressure value
(peak pressure) and the casting mold strength, it is also possible
to determine the quality of a green sand mold directly from the
pressure value (peak pressure) without converting to the casting
mold strength. The first and second embodiments mentioned above are
examples in which two or more pressure sensors are provided to the
plate. However, in the present invention, a configuration in which
one pressure sensor is provided to the plate is also possible. In
that case, it is desirable that the position at which the pressure
sensor is attached is near the model of the plate. Further, in such
cases when there is one pressure sensor, the output of the one
pressure sensor also indicates a value related to the casting mold
strength at a specific position of the casting mold. Therefore,
accuracy decreases but it is possible to use this value to perform
an evaluation of the casting mold quality.
[0176] Various embodiments of the present invention are described
above, but the above descriptions do not limit the present
invention and various modifications may be considered, including
deletion, addition, and replacement of constituent elements within
the technical scope of the present invention.
REFERENCE SIGNS LIST
[0177] 1 Casting mold molding device (frame casting mold molding)
[0178] 2 Plate [0179] 2a Central plate [0180] 2b Peripheral plate
[0181] 3 Model [0182] 4 Carrier [0183] 5 Metal frame [0184] 6
Filling frame [0185] 7 Squeeze head [0186] 8 Squeeze board [0187] 9
Table [0188] 10A-10H Green sand mold molding sensor [0189] 11
Wiring [0190] 12 Casting mold quality evaluation device [0191] 13
Liner [0192] 14 Bolt [0193] 15, 15' Receiving unit [0194] 16, 16'
Amplification unit [0195] 17 Input unit [0196] 18 Casting mold
strength calculation unit [0197] 19 Casting mold quality
determination unit [0198] 20 Display unit [0199] 21 Transmission
unit [0200] 22 Recording unit [0201] 23 Patlite [0202] 24 Pressure
value transmission unit [0203] 25 Integrated amplifier-recorder
[0204] 26 Computer [0205] 27 Louvered hopper [0206] 28 Louver
[0207] 29 Casting mold molding machine (flaskless molding machine)
[0208] 30 Shuttle dolly [0209] 31 Cope [0210] 32 Drag [0211] 33
Upper squeeze board [0212] 34 Lower squeeze board [0213] 35 Green
sand blowing-in port [0214] 36 Sand tank
* * * * *