Patent Application
20250083217
This application claims the benefit of Korean Patent Application No. 10-2023-0121627, filed on Sep. 13, 2023, which application is hereby incorporated herein by reference.
The present disclosure relates to a core molding system and method.
In general, a casting method is a method of injecting molten metal into a casting mold, changing the phase of the molten metal into a solid state, and forming a product having a preset shape.
For example, body parts and chassis parts of automobiles may be manufactured using a high-pressure casting method or a low-pressure casting method using a molten aluminum alloy.
In the casting method, a separate process for manufacturing a core is applied to realize a part having a complicated shape or a part having an undercut.
The core can be manufactured by a core molding system. In an example, the core molding system manufactures the core using core sand coated with a binder.
The core molding system can mold the core having the preset shape through a core mold by supplying the core sand into the core mold.
Meanwhile, the core molding system manufactures a core using core sand coated with an organic binder or core sand coated with an inorganic binder, depending on the rigidity of the cast part.
However, the process of manufacturing a core using core sand coated with an organic binder and the process of manufacturing a core using core sand coated with an inorganic binder are carried out in separate facilities.
Therefore, since the separate facilities are required to perform the foregoing processes, facility investment costs may increase.
The information described in this background section is only to enhance the understanding of the background of embodiments of the invention and may include information that does not form the already known related art.
The present disclosure relates to a core molding system and method. Particular embodiments relate to a core molding system and method for molding a sand core.
Embodiments of the present disclosure provide a core molding system and method capable of realizing, in one facility, a process of manufacturing a core using core sand coated with an organic binder and a process of manufacturing a core using core sand coated with an inorganic binder.
An exemplary embodiment of the present disclosure provides a core molding system including: i) an upper hopper partitioned to form a first accommodating part that accommodates first core sand coated with an organic binder and a second accommodating part that accommodates pure sand; ii) a lower hopper connected to the first accommodating part and the second accommodating part under the upper hopper to measure weights of the first core sand and the pure sand; iii) a mixer connected to the lower hopper to allow the first core sand to directly pass therethrough and accommodate the pure sand; iv) a binder supply unit connected to the mixer to supply an inorganic binder into the mixer; and v) a core mold that molds each of the first core sand that has directly passed through the mixer and second core sand in which the pure sand is coated with the inorganic binder in the mixer into a preset shape.
The core molding system may further include a blow head connected to the mixer to accommodate the first core sand or the second core sand and connected to a blow nozzle of the core mold.
The upper hopper may include a first opening/closing part that opens and closes the first accommodating part and a second opening/closing part that opens and closes the second accommodating part.
The lower hopper may include a third accommodating part that accommodates the first core sand or the pure sand, a measuring part installed in the third accommodating part, and a third opening/closing part that opens and closes the third accommodating part.
The mixer may include a fourth accommodating part that accommodates the pure sand, a mixing member installed in the fourth accommodating part, and a fourth opening/closing part that opens and closes the fourth accommodating part.
The binder supply unit may include a first supply part that accommodates a powder binder and supplies the powder binder into the mixer and a second supply part that accommodates a liquid binder and supplies the liquid binder into the mixer.
The first supply part may supply the powder binder into the mixer through a transfer screw.
The core molding system may further include a dust collector connected to the second accommodating part of the upper hopper to remove dust from the pure sand.
Another exemplary embodiment of the present disclosure provides a core molding method including: (a) putting first core sand coated with an organic binder into a first accommodating part of an upper hopper and putting pure sand into a second accommodating part of the upper hopper; (b) selecting one of an organic core molding mode and an inorganic core molding mode; (c) in the organic core molding mode, directly supplying the first core sand into a core mold; and (d) in the inorganic core molding mode, mixing the pure sand with an inorganic binder in a mixer and supplying second core sand in which the pure sand is coated with the inorganic binder into the core mold.
In the organic core molding mode, the first accommodating part may be opened and the second accommodating part may be closed, a third accommodating part of a lower hopper connected to the first accommodating part and the second accommodating part may be closed, the first core sand accommodated in the first accommodating part may be supplied into the third accommodating part, and a weight of the first core sand may be measured in the third accommodating part.
In the inorganic core molding mode, the first accommodating part may be closed, the second accommodating part may be opened, the third accommodating part may be closed, the pure sand accommodated in the second accommodating part may be supplied into the third accommodating part, and a weight of the pure sand may be measured in the third accommodating part.
In the organic core molding mode, the third accommodating part may be opened, a fourth accommodating part of the mixer may be opened, the first core sand that has passed directly through the fourth accommodating part from the third accommodating part may be supplied into the core mold, and the first core sand may be molded into a preset shape by the core mold.
In the organic core molding mode, the first core sand that has passed directly through the fourth accommodating part from the third accommodating part may be accommodated in a blow head, and the first core sand accommodated in the blow head may be supplied into the core mold.
In the inorganic core molding mode, the third accommodating part may be opened, a fourth accommodating part of the mixer may be closed, the pure sand accommodated in the third accommodating part may be supplied into the fourth accommodating part, the inorganic binder may be supplied into the fourth accommodating part, the pure sand and the inorganic binder may be mixed in the fourth accommodating part through a mixing member, the fourth accommodating part may be opened, the second core sand accommodated in the fourth accommodating part may be supplied into the core mold, and the second core sand may be molded into a preset shape by the core mold.
In the inorganic core molding mode, the second core sand accommodated in the fourth accommodating part may be supplied into a blow head, and the second core sand accommodated in the blow head may be supplied into the core mold.
The core molding system and method according to an exemplary embodiment of the present disclosure are capable of producing both a core using the first core sand and a core using the second core sand in one facility, thereby reducing facility investment costs.
Other effects that can be obtained or predicted from the exemplary embodiments of the present disclosure will be disclosed directly or implicitly in the detailed description of the exemplary embodiments of the present disclosure. That is, various effects predicted according to the exemplary embodiments of the present disclosure will be disclosed within the following detailed description.
Since the drawings are provided for reference in explaining exemplary embodiments of the present disclosure, the technical idea of the present disclosure should not be interpreted as limited to the accompanying drawings.
The drawings referred to above are not necessarily drawn to scale and should be understood as presenting somewhat simplified expressions of various preferred features illustrating the basic principles of embodiments of the present disclosure. For example, specific design features of embodiments of the present disclosure, including specific dimensions, orientations, locations, and shapes, will be determined in part by the particularly intended application and use environment.
Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings, so that they can be easily carried out by those of ordinary skill in the art to which the present disclosure pertains. However, the present disclosure may be implemented in various different forms and is not limited to the exemplary embodiments described herein.
In order to clearly explain embodiments of the present disclosure, parts irrelevant to the description will be omitted, and identical or similar components will be denoted by the same reference signs throughout the specification.
Since the size and thickness of each component shown in the drawings are arbitrarily shown for convenience of explanation, the embodiments of the present disclosure are not necessarily limited to what is illustrated in the drawings, and the thickness is exaggerated to clearly express various parts and regions.
In addition, terms such as “unit”, “part”, or “member” used herein refers to a unit of a comprehensive configuration that performs at least one function or operation.
The terminology used herein is for the purpose of describing particular exemplary embodiments and is not intended to limit the present disclosure. As used herein, singular forms are intended to include plural forms as well, unless the context clearly indicates otherwise.
It should be further noted that the terms “includes”, “including”, “comprises”, and/or “comprising” used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but they do not preclude the presence or addition of one or more other features, integers, steps, operations, components, and/or groups thereof.
As used herein, the term “coupled” specifies a physical relationship between two components in which the components are directly connected to each other or indirectly connected through at least one intermediate component.
Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.
Referring to
In an example, the cast part may include an automobile part such as a vehicle body part or a chassis part having a different stiffness and elongation depending on the purpose of use.
The casting method for manufacturing such a cast part may include a process of placing a core having a preset shape between a fixed die and a movable die of the casting mold and injecting molten metal between the fixed die, the movable die, and the core.
The core molding system 100 according to an exemplary embodiment of the present disclosure may be applied to a process of molding a core 1a or 1b into a preset shape as described above.
The core molding system 100 according to an exemplary embodiment of the present disclosure may mold the core 1a or 1b having the preset shape using first core sand 11 mixed with an organic binder or second core sand 12 mixed with an inorganic binder.
Here, since the compositions of the organic binder and the inorganic binder are obvious to those skilled in the art, detailed description thereof will be omitted.
Furthermore, the core molding system 100 according to an exemplary embodiment of the present disclosure is configured to produce both the core 1a using the first core sand 11 and the core 1b using the second core sand 12 in one facility.
To this end, the core molding system 100 according to an exemplary embodiment of the present disclosure includes an upper hopper 20, a lower hopper 30, a mixer 40, a binder supply unit 50, a blow head 60, and a core mold 70.
Referring to
The upper hopper 20 includes a first accommodating part 21 that accommodates the first core sand 11 and a second accommodating part 22 that accommodates the pure sand 14. The first accommodating part 21 and the second accommodating part 22 may be formed by partitioning the inside of the upper hopper 20 using a partition 20a.
Here, the second accommodating part 22 is connected to a dust collector 90. The dust collector 90 is configured to collect and remove dust from the pure sand 14 accommodated in the second accommodating part 22.
In addition, the upper hopper 20 includes a first opening/closing part 23 that opens and closes the first accommodating part 21 and a second opening/closing part 25 that opens and closes the second accommodating part 22.
The first opening/closing part 23 is disposed under the first accommodating part 21, and the second opening/closing part 25 is disposed under the second accommodating part 22. The first opening/closing part 23 and the second opening/closing part 25 may be moved back and forth by driving a driving source (e.g., a driving cylinder) that is obvious to those skilled in the art.
Referring to
The lower hopper 30 is disposed under the upper hopper 20 and is connected to the first accommodating part 21 and the second accommodating part 22 of the upper hopper 20.
The lower hopper 30 includes a third accommodating part 31, a measuring part 33, and a third opening/closing part 35.
The third accommodating part 31 may accommodate the first core sand 11 or the pure sand 14. The third accommodating part 31 is connected to the first accommodating part 21 and the second accommodating part 22 of the upper hopper 20.
The measuring part 33 is configured to measure a weight of each of the first core sand 11 discharged from the first accommodating part 21 and accommodated in the third accommodating part 31 and the pure sand 14 discharged from the second accommodating part 22 and accommodated in the third accommodating part 31 in a volumetric manner.
The measuring part 33 may measure a volume (or level) of the first core sand 11 or the pure sand 14 accommodated in the third accommodating part 31. The measuring part 33 may include, for example, a volume measuring system that is obvious to those skilled in the art.
In addition, the third opening/closing part 35 is configured to open and close the third accommodating part 31. The third opening/closing part 35 is disposed under the third accommodating part 31. The third opening/closing part 35 may be moved back and forth by driving a driving source (e.g., a driving cylinder) that is obvious to those skilled in the art.
Referring to
Furthermore, the mixer 40 is configured to mix the pure sand 14 with an inorganic binder 17 (see
The mixer 40 is disposed under the lower hopper 30 and is connected to the third accommodating part 31 of the lower hopper 30. The mixer 40 includes a fourth accommodating part 41, a mixing member 43, and a fourth opening/closing part 45.
The fourth accommodating part 41 may accommodate the pure sand 14. The fourth accommodating part 41 is connected to the third accommodating part 31 of the lower hopper 30.
The mixing member 43 is installed in the fourth accommodating part 41 to mix the pure sand 14 and the inorganic binder 17. For example, the mixing member 43 may include a mixing blade that is rotated by driving a motor (not illustrated).
In addition, the fourth opening/closing part 45 is configured to open and close the fourth accommodating part 41. The fourth opening/closing part 45 is disposed under the fourth accommodating part 41. The fourth opening/closing part 45 may be moved back and forth by driving a driving source (e.g., a driving cylinder) that is obvious to those skilled in the art.
Referring to
The binder supply unit 50 is connected to the mixer 40. The binder supply unit 50 includes a first supply part 51 and a second supply part 52.
The first supply part 51 is configured to supply the powder binder 17a to the fourth accommodating part 41 of the mixer 40. The first supply part 51 is connected to a first binder injection part 47 of the mixer 40 through a first supply line 53.
In an example, the first supply part 51 may supply the powder binder 17a to the first binder injection part 47 of the mixer 40 through a transfer screw 55.
Here, the transfer screw 55 may supply the powder binder 17a to the first binder injection part 47 through the first supply line 53, while rotating by driving a motor (not illustrated). In addition, a first valve 54 is installed in the first supply line 53.
The second supply part 52 is configured to supply the liquid binder 17b to the fourth accommodating part 41 of the mixer 40. The second supply part 52 is connected to a second binder injection part 49 of the mixer 40 through a second supply line 57.
The second supply part 52 may supply the liquid binder 17b to the second binder injection part 49 through the second supply line 57 by operating a pump (not illustrated). In addition, a second valve 58 is installed in the second supply line 57.
Therefore, in a state where the pure sand 14 is accommodated in the fourth accommodating part 41 of the mixer 40, the first supply part 51 supplies the powder binder 17a to the fourth accommodating part 41, and the second supply part 52 supplies the liquid binder 17b to the fourth accommodating part 41.
As a result, the mixer 40 may mix the pure sand 14, the powder binder 17a, and the liquid binder 17b by the mixing member 43 in the fourth accommodating part 41, thereby producing the second core sand 12 in which the pure sand 14 is coated with the inorganic binder 17.
Referring to
The blow head 60 is connected to the fourth accommodating part 41 of the mixer 40 as illustrated in
Referring to
The core mold 70 includes a lower die 71 and an upper die 73 that may be joined to and released from each other. In addition, the core mold 70 includes a blow nozzle 75 installed in the upper die 73.
When the lower die 71 and the upper die 73 are joined to each other, a core molding space 77 is formed between the lower die 71 and the upper die 73. The blow nozzle 75 is connected to the core molding space 77 and is connected to the blow head 60 mentioned above.
Here, the first core sand 11 or the second core sand 12 accommodated in the blow head 60 may be filled into the core molding space 77 through the blow nozzle 75 by air pressure.
In a state where the lower die 71 and the upper die 73 are preheated, the first core sand 11 or the second core sand 12 may be filled into the core molding space 77 and pressurized to a preset pressure through a temper pin assembly (not illustrated).
Therefore, the first core sand 11 or the second core sand 12 may be molded into the core 1a or 1b having the preset shape in the core molding space 77. The core 1a or 1b may be ejected by an ejecting unit (not illustrated) in a state where the lower die 71 and the upper die 73 are released from each other.
Hereinafter, a core molding method using the core molding system 100 configured as described above according to an exemplary embodiment of the present disclosure will be described in detail with reference to
Referring to
Also, the third accommodating part 31 of the lower hopper 30 is closed by the third opening/closing part 35, and the fourth accommodating part 41 of the mixer 40 is closed by the fourth opening/closing part 45.
In addition, in the binder supply unit 50, the first supply line 53 of the first supply part 51 is closed by the first valve 54, and the second supply line 57 of the second supply part 52 is closed by the second valve 58.
Furthermore, the lower die 71 and the upper die 73 of the core mold 70 are joined to each other and are preheated to a preset temperature.
In this state, the first core sand 11, in which the pure sand 14 is coated with the organic binder 15, is put into the first accommodating part 21 of the upper hopper 20. Then, the pure sand 14 is put into the second accommodating part 22 of the upper hopper 20 (S11).
Then, an operator selects one of an organic core molding mode M1 and an inorganic core molding mode M2 (S12).
Here, the organic core molding mode M1 may be defined as a mode in which the core 1a having a preset shape is formed using the first core sand 11 in which the pure sand 14 is coated with the organic binder 15. In addition, the inorganic core molding mode M2 may be defined as a mode in which the core 1b having a preset shape is molded using the second core sand 12 in which the pure sand 14 is coated with the inorganic binder 17.
In an example, the organic core molding mode M1 or the inorganic core molding mode M2 as described above may be implemented by a screen touch operation or a remote operation of a control panel (or an operation panel).
Meanwhile, referring to
Accordingly, the measuring part 33 measures a weight of the first core sand 11 accommodated in the third accommodating part 31 in a volumetric manner (S21).
Next, when the weight of the first core sand 11 is measured to a preset weight by the measuring part 33, the first opening/closing part 23 closes the first accommodating part 21 of the upper hopper 20.
Subsequently, the third opening/closing part 35 opens the third accommodating part 31 of the lower hopper 30, and the fourth opening/closing part 45 opens the fourth accommodating part 41 of the mixer 40. At this time, the mixing member 43 of the mixer 40 is in a non-operating state.
Then, the first core sand 11 is discharged from the third accommodating part 31 and supplied into the fourth accommodating part 41 of the mixer 40. Here, the first core sand 11 passes directly through the fourth accommodating part 41 (S22). The first core sand 11 is accommodated in the blow head 60.
When the first core sand 11 is accommodated in the blow head 60 in this manner, the third opening/closing part 35 closes the third accommodating part 31 of the lower hopper 30, and the fourth opening/closing part 45 closes the fourth accommodating part 41 of the mixer 40.
Next, the first core sand 11 accommodated in the blow head 60 is filled into the core molding space 77 between the lower die 71 and the upper die 73 through the blow nozzle 75 (S23).
As a result, the first core sand 11 is molded into the core 1a having a preset shape in the core molding space 77 (S24). The core 1a is ejected by an ejecting unit (not illustrated) in a state where the lower die 71 and the upper die 73 are released from each other.
On the other hand, referring to
Accordingly, the measuring part 33 measures a weight of the pure sand 14 accommodated in the third accommodating part 31 in a volumetric manner (S31).
Next, when the weight of the pure sand 14 is measured to a preset weight by the measuring part 33, the second opening/closing part 25 closes the second accommodating part 22 of the upper hopper 20.
Subsequently, the third opening/closing part 35 opens the third accommodating part 31 of the lower hopper 30. Then, the pure sand 14 is discharged from the third accommodating part 31 and supplied into the fourth accommodating part 41 of the mixer 40 (S32). Here, the fourth accommodating part 41 of the mixer 40 is closed by the fourth opening/closing part 45 to accommodate the pure sand 14.
In this process, the first supply part 51 of the binder supply unit 50 opens the first supply line 53 by the first valve 54, and the powder binder 17a is supplied into the fourth accommodating part 41 of the mixer 40 through the first supply line 53. At this time, the powder binder 17a may be supplied into the fourth accommodating part 41 of the mixer 40 through the first supply line 53 by rotating the transfer screw 55.
In addition, the second supply part 52 of the binder supply unit 50 opens the second supply line 57 by the second valve 58 and supplies the liquid binder 17b into the fourth accommodating part 41 of the mixer 40 through the second supply line 57.
That is, the binder supply unit 50 supplies the inorganic binder 17 including the powder binder 17a and the liquid binder 17b into the fourth accommodating part 41 of the mixer 40 by the first supply part 51 and the second supply part 52 (S33).
In this process, the mixing member 43 of the mixer 40 operates. Accordingly, the mixing member 43 mixes the pure sand 14, the powder binder 17a, and the liquid binder 17b in the fourth accommodating part 41 (S34). As a result, the second core sand 12, in which the pure sand 14 is coated with the inorganic binder 17, is produced (S35).
Next, the fourth opening/closing part 45 opens the fourth accommodating part 41 of the mixer 40. Then, the second core sand 12 is discharged from the fourth accommodating part 41 and accommodated in the blow head 60.
When the second core sand 12 is accommodated in the blow head 60 in this manner, the third opening/closing part 35 closes the third accommodating part 31 of the lower hopper 30, and the fourth opening/closing part 45 closes the fourth accommodating part 41 of the mixer 40.
Next, the second core sand 12 accommodated in the blow head 60 is filled into the core molding space 77 between the lower die 71 and the upper die 73 through the blow nozzle 75 (S36).
As a result, the second core sand 12 is molded into the core 1b having a preset shape in the core molding space 77 (S37). The core 1b is ejected by an ejecting unit (not illustrated) in a state where the lower die 71 and the upper die 73 are released from each other.
Through a series of processes as described above, the core molding system 100 according to an exemplary embodiment of the present disclosure is capable of individually molding the core 1a using the first core sand 11, in which the pure sand 14 is coated with the organic binder 15, and the core 1b using the second core sand 12, in which the pure sand 14 is coated with the inorganic binder 17.
The core molding system 100 according to an exemplary embodiment of the present disclosure as described so far is capable of producing both the core 1a using the first core sand 11 and the core 1b using the second core sand 12 in one facility.
As a result, the core molding system 100 according to an exemplary embodiment of the present disclosure is capable of reducing facility investment costs and improving productivity of the cores 1a and 1b.
Although the preferred exemplary embodiments of the present disclosure have been described above, the present disclosure is not limited thereto, and it may be modified in various ways within the scope of the claims, the detailed description of embodiments of the invention, and the accompanying drawings, and the modifications fall within the scope of the present disclosure.
The following reference identifiers may be used in connection with the accompanying drawings to describe various features of embodiments of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2023-0121627 | Sep 2023 | KR | national |
