FLASK REMOVAL UNIT, MODELING MACHINE, AND FLASK REMOVAL METHOD

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on and claims the benefit of priority from Japanese Patent Application No. 2023-194975 filed on Nov. 16, 2023, and the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a flask removal unit, a modeling machine, and a flask removal method.

BACKGROUND

Japanese Unexamined Patent Publication No. 2006-315012 discloses a molding apparatus including a flask removal mechanism for removing a cope and a drag from an upper flask and a lower flask. The flask removal mechanism removes the cope and the drag from the upper and lower flask by contracting a cylinder to lower a removal plate and a mold receiving table in conjunction with each other. The removed cope and drag are mounted on the mold receiving table. Subsequently, the cope and the drag on the mold receiving table is extruded by a mold discharge device.

SUMMARY

In a case where the molding apparatus described in Japanese Unexamined Patent Publication No. 2006-315012 continuously molds, a cycle of extruding the cope and the drag on the mold receiving table, separating the upper flask and the lower flask, clamping a match plate between the upper flask and the lower flask, filling the upper and lower flask with sand, and squeezing is repeated. The molding apparatus that repeats such a cycle has room for improvement from the viewpoint of improving productivity.

The present disclosure provides a technique capable of shortening a cycle time of removing of a flask.

A flask removal unit according to an aspect of the present disclosure is a flask removal flask unit that removes a cope and a drag between which a pattern member is disposed from an upper and lower flask. The flask removal unit includes an upper flask, a lower flask, a guide member, a flask moving unit, an extrusion unit, a support unit, and a control unit. The upper flask has a cope formed inside, and has open an upper end and lower end. The lower flask has a drag formed inside, and has open upper end and lower end. At least one of the upper flask and the lower flask is movably connected to the guide member. The flask moving unit moves at least one of the upper flask and the lower flask along the guide member. The extrusion unit includes an extrusion member that relatively moves to the upper and lower flask obtained by coupling the upper flask and the lower flask to each other. The extrusion unit extrudes a mold obtained by combining the cope and the drag with each other from the upper and lower flask. The support unit includes a support member that relatively move to the upper and lower flask. The support unit moves together with the extrusion member to support the mold extruded from the upper and lower flask by the extrusion unit, and conveys the mold extruded from the upper and lower flask to an unloading position where the mold is unloaded. The control unit controls the flask moving unit, the extrusion unit, and the support unit. The control unit performs control such that at least one of the upper flask and the lower flask is moved to a position where the pattern member can be disposed between the upper flask and the lower flask in a period in which the support unit conveys the mold to the unloading position.

A flask removal method according to another aspect of the present disclosure is a flask removal method for removing a cope and a drag between which a pattern member is disposed from an upper and lower flask. The flask removal method includes the following steps (a) to (c). (a) A step of extruding a mold obtained by combining the cope and the drag from an upper and lower flask obtained by coupling an upper flask having the cope formed inside and having open upper end and lower end and a lower flask having the drag formed inside and having open upper end and lower end. (b) A step of conveying the mold extruded from the upper and lower flask to an unloading position where the mold is unloaded. (c) A step of moving at least one of the upper flask and the lower flask to a position where the pattern member can be disposed between the upper flask and the lower flask. The step of moving at least one of the upper flask and the lower flask is performed in a period in which the step of conveying the mold to the unloading position is performed.

According to the present disclosure, the cycle time of the removing of the flask can be shortened.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view illustrating an example of a modeling machine according to an embodiment;

FIG. 2 is a side view of a flask unit illustrated in FIG. 1;

FIG. 3 is a front view of the flask unit illustrated in FIG. 1;

FIG. 4 is a front view illustrating an example of a state of a coupled upper and lower flask of the flask unit illustrated in FIG. 1 are coupled;

FIG. 5 is a side view illustrating an example of the modeling machine in a state of the coupled upper and lower flask;

FIG. 6 is a side view illustrating an example of the modeling machine in a state where the flask unit is rotated;

FIG. 7 is a plan view illustrating an example of a molding unit before squeezing;

FIG. 8A is a front view illustrating an example of a guide fixing unit, FIG. 8B is a front view illustrating an example of a guide fixing unit;

FIG. 9 is a flowchart illustrating an example of a molding method according to the embodiment;

FIG. 10 is a plan view illustrating an example of the molding unit during squeezing;

FIG. 11A is a sectional view illustrating an example of the upper and lower flask and a mold, FIG. 11B is a sectional view illustrating a state where the mold is extruded from the upper and lower flask, FIG. 11C is a sectional view illustrating a state where the mold is conveyed to a conveyance position, FIG. 11D is a sectional view illustrating a state where a pattern member is conveyed between the upper flask and the lower flask, and FIG. 11E is a sectional view illustrating a state where the flask unit is rotated from a first position to a second position;

FIG. 12 is a flowchart illustrating an example of a flask removal method according to the embodiment;

FIG. 13 is a front view illustrating an example of a modeling machine according to a modification; and

FIG. 14A is a sectional view illustrating a part of a molding unit according to a modification, FIG. 14B is a sectional view illustrating a part of a molding unit according to a modification, and FIG. 14C is a sectional view illustrating a part of a molding unit according to a modification.

DETAILED DESCRIPTION
Example of Embodiment of Present Disclosure

Hereinafter, an embodiment of the present disclosure will be described with reference to the drawings. Note that, in the following description, the same or equivalent elements are denoted by the same reference signs, and redundant description will not be repeated. The dimensional ratios in the drawings do not necessarily coincide with those in the description. The words “upper”, “lower”, “left”, and “right” are based on the illustrated state and are used for convenience.

[Outline of Modeling Machine]

FIG. 1 is a side view illustrating an example of a modeling machine according to the embodiment. In the drawing, an X direction and a Y direction are horizontal directions, and a Z direction is a vertical direction. The X direction, the Y direction, and the Z direction are axial directions orthogonal to each other in an orthogonal coordinate system of a three-dimensional space. Hereinafter, the Z direction is also referred to as an up-down direction. A modeling machine 100 illustrated in FIG. 1 is a modeling machine that molds a cope and a drag. The modeling machine 100 includes a flask unit 1, a flask removal unit 10, a rotation unit 102, a pattern exchange unit 103, a squeeze unit 104, and an unloading unit 108. Details of the unloading unit 108 will be described with reference to FIG. 11E.

The flask unit 1 is configured to be movable between a first position 101 and a second position 105. The first position 101 is a work position set in the modeling machine 100, and is a position where disposition of a pattern between upper and lower flasks, removing of the mold, and the like are performed.

The second position 105 is a position where sand is put into the upper and lower flask and squeezing, and the like are performed in the modeling machine 100.

The flask unit 1 illustrated in FIG. 1 is positioned at the first position 101. The flask unit 1 includes an upper flask 2 and an lower flask 3. Each of the upper flask 2 and the lower flask 3 is a box-shaped flask body in which an upper end portion and a lower end portion are open. The upper flask 2 and the lower flask 3 move to approach each other, and are coupled so as to clamp a pattern member 8 loaded in by the pattern exchange unit 103. The pattern member 8 is a plate member on which the pattern can be disposed. The pattern is disposed on at least one of an upper surface and a lower surface of the pattern member 8. Hereinafter, the coupled upper flask 2 and lower flask 3 is also referred to as an upper and lower flask 23.

The rotation unit 102 rotates the flask unit 1 including the upper flask 2 and the lower flask 3 clamped by the pattern member 8 to be positioned on the same horizontal plane (XY plane). The flask unit 1 rotated by the rotation unit 102 moves to the second position 105 provided above the first position 101 and is incorporated into the squeeze unit 104. At the second position 105, the upper flask 2 and the lower flask 3 incorporated in the squeeze unit 104 are filled with sand. Sand filling the upper flask 2 and the lower flask 3 is simultaneously formed as a cope in the upper flask 2 and a drag in the lower flask 3, respectively, by being pressurized, for example, along the X direction by the squeeze unit 104. Thereafter, the flask unit 1 is rotated from the second position 105 to the first position 101 by the rotation unit 102. At the first position 101, the upper flask 2 and the lower flask 3 are separated from each other, the pattern member 8 is removed from between the upper flask 2 and the lower flask 3, and then the upper flask 2 and the lower flask 3 are mold-assembled. The cope and the drag in the mold-assembled state are removed from the upper and lower flask 23 and are unloaded from the machine. As described above, the modeling machine 100 molds a cope and a drag of flaskless.

[Details of Flask Unit]

FIG. 2 is a side view of the flask unit illustrated in FIG. 1, and FIG. 3 is a front view of the flask unit illustrated in FIG. 1. FIGS. 1 to 3 illustrate an initial state where the upper flask and the lower flask are separated from each other. FIG. 4 is a front view illustrating an example of a state where upper and lower flask of the flask unit illustrated in FIG. 1 are coupled. As illustrated in FIGS. 1 to 4, the flask unit 1 rotatable by the rotation unit 102 includes the upper flask 2, the lower flask 3, guide members 4 and 4, and an upper squeeze plate 7. The upper squeeze plate 7 is an example of an extrusion member.

At the first position 101, the upper flask 2 is disposed above a position where the pattern member 8 is loaded in and between the guide members 4 and 4 in the Y direction. The upper flask 2 has a space in which the pattern disposed on the upper surface of the pattern member 8 can be accommodated. The lower end portion of the upper flask 2 can abut on, for example, the upper surface of the pattern member 8. A sand introduction hole 2a penetrating from an outside to an internal space is provided in a side wall portion of the upper flask 2.

At the first position 101, the lower flask 3 is disposed below the position where the pattern member 8 is loaded in and between the guide members 4 and 4 in the Y direction. The lower flask 3 has a space in which the pattern disposed on the lower surface of the pattern member 8 can be accommodated. The upper end portion of the lower flask 3 can abut on, for example, the lower surface of the pattern member 8. A sand introduction hole 3a penetrating from an outside to an internal space is provided in a side wall portion of the lower flask 3.

The guide member 4 is a rod member that guides the upper flask 2 and the lower flask 3, and extends in the up-down direction in FIGS. 1 to 4. The guide member 4 has, for example, a columnar shape. The upper flask 2 and the lower flask 3 are movably connected to the guide members 4 and 4. The upper flask 2 is movably connected to the guide members 4 and 4 by upper flask connection units 11 and 11. Upper flask adjustment cylinders 13 and 13 are connected to the upper flask 2. The upper flask adjustment cylinders 13 and 13 are examples of a flask moving unit. The upper flask 2 moves by a driving force of the upper flask adjustment cylinders 13 and 13. The lower flask 3 is movably connected to the guide members 4 and 4 by lower flask connection units 12 and 12. Lower flask adjustment cylinders 14 and 14 are connected to the lower flask 3. The lower flask adjustment cylinders 14 and 14 are examples of a flask moving unit. The lower flask 3 moves by a driving force of the lower flask adjustment cylinders 14 and 14. As described above, the upper flask adjustment cylinders 13 and the lower flask adjustment cylinders 14 relatively move the upper flask 2 and the lower flask 3 along the guide members 4 and 4 such that the pattern member 8 is clamped and released by the upper flask 2 and the lower flask 3. The upper flask adjustment cylinders 13 and the lower flask adjustment cylinders 14 may be hydraulic cylinders, air cylinders, or electric cylinders. One or both of the upper flask 2 and the lower flask 3 move to approach each other, and as illustrated in FIG. 4, the upper flask and the lower flask are coupled while clamping the pattern member 8. A groove along a circumferential direction of the rod member is formed at a terminal end portion of the guide member 4. The guide member 4 has a distal end portion coupled to the upper squeeze plate 7 and the terminal end portion in which the groove is formed.

The upper squeeze plate 7 is a plate member that can enter into the upper flask 2 from an opening at an upper end of the upper flask 2. The upper squeeze plate 7 defines a molding space for molding the cope together with the upper flask 2 and the pattern member 8. The upper squeeze plate 7 is coupled to a frame 15 and the guide members 4 and 4. In FIGS. 1 to 4, the frame 15 is positioned above the upper squeeze plate 7. The frame 15 includes an attachment member coupled to the guide members 4 and 4, and a squeeze pedestal that couples the attachment member and the upper squeeze plate 7 to each other. The attachment member has a plate shape and includes both ends coupled to the guide members 4 and 4. The squeeze pedestal is positioned between the guide members 4 and 4 and extends in the up-down direction between the attachment member and the upper squeeze plate 7.

As an example, the guide members 4 and 4 are disposed at positions symmetrical with respect to center lines passing through centers of the upper flask 2 and the lower flask 3. For example, in a case where the flask unit 1 is disposed at the first position 101, the guide members 4 and 4 are disposed at positions symmetrical with respect to the center lines passing through the centers of the upper flask 2 and the lower flask 3 in the XY plane. The positions symmetrical with respect to the center lines passing through the centers of the upper flask 2 and the lower flask 3 are positions where the guide members 4 and 4 can stably support the upper flask 2 and the lower flask 3 and mold deviation and uneven wear are less likely to occur. Further, the positions symmetrical with respect to the center lines passing through the centers of the upper flask 2 and the lower flask 3 are positions where the guide members 4 and 4 can stably support the upper squeeze plate 7 and are positions where bias of a squeeze force is less likely to occur.

[Details of Rotation Unit]

FIG. 5 is a side view illustrating an example of the modeling machine in a state where the upper and lower flask are coupled. FIG. 6 is a side view illustrating an example of the modeling machine in a state where the flask unit is rotated. As illustrated in FIGS. 5 and 6, the rotation unit 102 is provided on a support 22 erected on a base 21 of the modeling machine 100. The support 22 is disposed on a side of the first position 101 (X-axis positive direction). The rotation unit 102 includes an attachment frame 31, a rotation shaft 32, and rotation drive units 33 and 33. The guide members 4 and 4 are fixed to the attachment frame 31. As a result, the attachment frame 31 supports the flask unit 1. The attachment frame 31 is open such that the pattern member 8 can be loaded in and unloaded from the pattern exchange unit 103 to the first position 101.

The rotation shaft 32 is a member provided on the support 22 to extend in the Y direction. The rotation shaft 32 is provided on the support 22 to be rotatable around an axis. The rotation drive unit 33 is a drive source for rotating the flask unit 1. The rotation drive unit 33 is, for example, a cylinder having a rod that can expand and contract in an axial direction. A terminal end of the rotation drive unit 33 is rotatably fixed to the base 21 around an axis extending in the Y direction, and a distal end thereof is rotatably fixed to the attachment frame 31 around the axis extending in the Y direction. The rod of each of the rotation drive units 33 and 33 expands by the cylinder, and thus, a force in an up direction (a clockwise direction around the rotation shaft 32) is applied to the attachment frame 31, and the attachment frame 31 can move to the second position 105. The rod of each of the rotation drive units 33 and 33 is contracted by the cylinder, a force in a down direction (a counterclockwise direction around the rotation shaft 32) is applied to the attachment frame 31, and the attachment frame 31 can move to the first position 101. As described above, the rotation unit 102 can rotate the flask unit 1 together with the attachment frame 31. The rotation unit 102 rotates the flask unit 1 between the first position 101 where flask removal is performed and the second position 105 where the squeeze is performed.

[Details of Pattern Exchange Unit]

As illustrated in FIG. 1, the pattern exchange unit 103 is disposed on the side of (X-axis positive direction) of the first position 101. The pattern exchange unit 103 includes a conveyance unit 40 and a conveyance change unit 46. The conveyance unit 40 loads and unload the pattern member 8 in and from between the upper flask 2 and the lower flask 3. The conveyance unit 40 includes a conveyance base 41, a conveyance rail 42, an arm moving unit 43, an arm 44, and a mounting unit 45.

The conveyance base 41 supports the conveyance rail 42. The conveyance rail 42 extends in a direction (X-axis direction) of advancing and retracting with respect to the first position 101. As an example, the conveyance rail 42 has a linear shape, and moves two arm units along a rail extending direction. A first arm unit includes a first arm moving unit 43a, a first arm 44a, and a first mounting unit 45a. The first arm moving unit 43a includes, for example, a motor and moves on the conveyance rail 42. The motor included in the first arm moving unit 43a is, for example, an electric motor or a hydraulic motor. The first arm 44a is provided in the first arm moving unit 43a to support the first mounting unit 45a. The pattern member 8 can be mounted on the first mounting unit 45a. A second arm unit has the same configuration as the first arm unit, and includes a second arm moving unit 43b, a second arm 44b, and a second mounting unit 45b. The first arm unit and the second arm unit are disposed at both ends of the conveyance rail 42.

The conveyance change unit 46 supports the conveyance base 41 and rotates the conveyance base 41. The conveyance change unit 46 rotates the conveyance base 41 such that the arm units disposed at end portions of the conveyance rail 42 face the first position 101. The arm units positioned at positions facing the first position 101 move on the conveyance rail 42 to approach the first position 101 by the arm moving unit 43, the arm 44 is disposed between the guide members 4 and 4 at the first position 101, and the pattern member 8 is loaded and unloaded by the mounting unit 45.

In a case where the first arm unit faces the first position 101, the second arm unit is positioned at a pattern preparation position 40b. The pattern preparation position 40b is a position where a new pattern member 8 is mounted on the mounting unit 45 and a position where a used pattern member 8 is collected.

For example, in a case where the pattern member 8 is exchanged, the first mounting unit 45a of the first arm unit receives the used pattern member 8 from the first position 101 and unloads the pattern member. The second mounting unit 45b of the second arm unit receives the new pattern member 8 at the pattern preparation position 40b. Subsequently, the first arm moving unit 43a causes the first mounting unit 45a having received the used pattern member 8 to retreat from the first position 101 toward a center (X-axis positive direction) of the conveyance base 41. The second arm moving unit 43b causes the second mounting unit 45b having received the new pattern member 8 to retreat from the pattern preparation position 40b toward a center (X-axis negative direction) of the conveyance base 41. As a result, it is possible to suppress contact of the rotating first arm unit and second arm unit with components of the modeling machine 100 such as the flask unit 1 when the conveyance base 41 to be described later rotates. Subsequently, the conveyance change unit 46 rotates the conveyance base 41 by 180 degrees. As a result, the second mounting unit 45b on which the new pattern member 8 is mounted moves to the position facing the first position 101, and the first mounting unit 45a on which the used pattern member 8 is mounted moves to the pattern preparation position 40b. The second mounting unit 45b of the second arm unit loads in the new pattern member 8 at the first position 101. The pattern member 8 mounted on the first mounting unit 45a of the first arm unit is collected by a worker or the like at the pattern preparation position 40b. The exchange of the pattern member 8 is thus completed.

[Details of Squeeze Unit]

FIG. 7 is a plan view illustrating an example of a molding unit before squeezing. As illustrated in FIG. 6, a molding unit 1A illustrated in FIG. 7 is formed such that the flask unit 1 is positioned at the second position 105 and is incorporated in the squeeze unit 104. Molding spaces of the upper flask 2 and the lower flask 3 are formed by being incorporated into the squeeze unit 104. Thereafter, sand is supplied to the molding space of the upper and lower flask 23, and is squeezed by the squeeze unit 104. Details will be described below.

The squeeze unit 104 includes a molding support unit 51, molding rails 52 and 52, a lower squeeze plate 6, a squeeze cylinder 60, and guide fixing units 70 and 70.

The molding support unit 51 is a flask-shaped member fixed to the support 22 and extending in the horizontal direction. The molding support unit 51 has a space capable of accommodating the flask unit 1 inside the flask. The space is open in the up-down direction.

The molding rails 52 and 52 guide the squeeze cylinder 60 along the X axis. The molding rails 52 and 52 are provided, for example, on a wall surface inside the molding support unit 51. The molding rails 52 and 52 face each other in the Y direction and extend in a squeeze direction (X direction). The number or installation positions of the molding rails may be appropriately changed depending on a shape of the molding support unit 51. As described above, the squeeze cylinder 60 is movably disposed with respect to the upper and lower flask 23.

The lower squeeze plate 6 is a plate member that can enter into the lower flask 3 from an opening at a lower end of the lower flask 3. The lower squeeze plate 6 defines a molding space for molding the drag together with the lower flask 3 and the pattern member 8. The lower squeeze plate 6 is disposed to clamp the upper and lower flask 23 between the lower squeeze plate and the upper squeeze plate 7. The lower squeeze plate 6 enters into the lower flask 3 by driving of the squeeze cylinder 60.

The squeeze cylinder 60 includes a rod 61 and a cylinder body 63. The lower squeeze plate 6 is fixed to an end portion of the rod 61 via a squeeze pedestal 62. The cylinder body 63 controls an expansion and contraction amount and a timing of the rod 61. The squeeze cylinder 60 may be a hydraulic cylinder, an air cylinder, or an electric cylinder.

The cylinder body 63 has an attachment member 64 and is disposed on the molding rails 52 and 52 described above via the attachment member 64. A rod of the moving cylinder 65 for moving the squeeze cylinder 60 along the X axis is connected to the attachment member 64 (see FIG. 1). The moving cylinder 65 may be a hydraulic cylinder, an air cylinder, or an electric cylinder. The rod of the moving cylinder 65 expands, and thus, the cylinder body 63 approaches the lower flask 3. The cylinder body 63 expands the rod 61 in a state of approaching the lower flask 3. As a result, the squeeze pedestal 62 presses the lower squeeze plate 6 in the X-axis positive direction, and causes the lower squeeze plate 6 to enter the opening of the lower flask 3. As a result, the molding space for molding the drag is defined.

The attachment member 64 of the cylinder body 63 has first opening portions 64a and 64a into which the terminal end portions of the guide members 4 and 4 can be inserted. The first opening portion 64a penetrates along the X axis. A diameter of the first opening portion 64a is larger than a diameter of the terminal end portion of the guide member 4. Accordingly, the guide member 4 can be inserted into the first opening portion 64a of the attachment member 64 of the cylinder body 63. The movement of the guide member 4 inserted into the first opening portion 64a in the X-axis positive direction is restricted by the guide fixing unit 70 provided in the attachment member 64. The guide member 4 inserted into the first opening portion 64a is fixed to the attachment member 64 to restrict the movement in the X-axis positive direction, and thus, relative positions of the guide members 4 and 4 to the upper squeeze plate 7 and the cylinder body 63 are fixed at the time of squeezing. As a result, the movement of the cylinder body 63 and the movement of the upper squeeze plate 7 are interlocked at the time of squeezing. Note that, when the movement of the guide members 4 and 4 in the X-axis positive direction is restricted, the upper squeeze plate 7 enters into the upper flask 2 from the opening at the upper end of the upper flask 2. As a result, the molding space for molding the cope is defined by the upper squeeze plate 7, the upper flask 2, and the pattern member 8.

FIG. 8A is a front view illustrating an example of the guide fixing unit. FIG. 8B is a front view illustrating an example of the guide fixing unit. As illustrated in FIGS. 7, 8A and 8B, the guide fixing units 70 and 70 are provided on attachment member 64, and restrict the movement of the guide members 4 inserted into the first opening portions 64a in the X-axis positive direction. The guide fixing units 70 and 70 are provided for the guide members 4 and 4. The guide fixing unit 70 includes fixing pedestals 71 and 71, fixing cylinders 72 and 72, and wedge members 74 and 74.

The fixing pedestal 71 is, for example, a plate member erected on the attachment member 64 of the squeeze cylinder 60, and supports the fixing cylinder 72. The fixing cylinders 72 and 72 have fixing rods 73 and 73. The fixing rod 73 extends from the fixing cylinder 72 toward the first opening portion 64a. The fixing rod 73 expands and contracts by driving of the fixing cylinder 72. For example, the wedge member 74 is provided at a lower end of the fixing rod 73. The wedge member 74 is a hook member locked to the groove at the terminal end portion of the guide member 4. As an example, the wedge member 74 has a notch along the groove at the terminal end portion of the guide member 4, and locks the guide member 4 by fitting the groove at the terminal end portion of the guide member 4 into the notch. Note that, a shape of the wedge member 74 is not particularly limited, and may be any shape as long as the wedge member can be locked to the guide member 4. A pair of guide rails (not illustrated) supported by the attachment member 64 and the fixing pedestal 71 and extending from a position of the fixing cylinder 72 toward the first opening portion 64a may be provided in the guide fixing unit 70. The pair of guide rails is provided to approach or come into contact with an outer edge of the wedge member 74, and guides the wedge member 74 to be movable more stably.

In a case where the squeeze cylinder 60 moves in the X-axis positive direction, the terminal end portions of the guide members 4 and 4 are inserted into the first opening portions 64a and 64a of the attachment member 64 and the entire terminal end portions completely protrude from the first opening portions 64a, the wedge members 74 and 74 are engaged with the grooves at the terminal end portions of the guide members 4 and 4. Specifically, the fixing cylinders 72 and 72 are driven, and thus, the fixing rods 73 and 73 expand, and the wedge members 74 and 74 move downward. The wedge members 74 and 74 reach groove surfaces of the terminal end portions of the guide members 4 and 4, and the guide members 4 and 4 are locked. In a case where the guide members 4 and 4 are locked by the wedge members 74 and 74, when the guide members 4 and 4 attempt to move in the X-axis positive direction, wall surfaces defining the grooves of the guide members 4 and 4 abut on the wedge members 74 and 74. Thus, the movement of the guide members 4 and 4 in the X-axis positive direction is restricted. After squeezing is completed, the fixing cylinders 72 and 72 are driven, the fixing rods 73 and 73 shrink, and the wedge members 74 and 74 move upward. Thus, the engagement between the guide members 4 and 4 and the wedge members 74 and 74 is released.

After the guide members 4 and 4 are fixed to the cylinder body 63, sand is supplied to the molding space of the upper and lower flask 23. A sand supply device 106 that supplies sand will be described later. Squeezing is performed after sand fills the molding space. The squeeze cylinder 60 expands the rod 61 in the X-axis positive direction, and causes the lower squeeze plate 6 to enter the lower flask 3. The cylinder body 63 moves in the X-axis negative direction by a reaction force of a pressure applied to sand in the lower flask 3, the guide members 4 and 4 are pulled in the X-axis negative direction via the wedge members 74 and 74 in accordance with the movement of the cylinder body 63, and the upper squeeze plate 7 enters the upper flask 2. As described above, the lower squeeze plate 6 and the upper squeeze plate 7 move toward the pattern member 8, and thus, squeezing is performed.

[Details of Sand Supply Device]

The sand supply device 106 is disposed at the second position 105. As illustrated in FIG. 6, the sand supply device 106 includes a storage tank 106a that stores sand, and a supply unit 106b that supplies sand supplied from the storage tank 106a to the upper flask 2 and the lower flask 3. The storage tank 106a has, for example, a box shape and has a space in which sand can be stored. A shape of the storage tank 106a is not limited to the box shape, and may be, for example, a cylindrical shape. The supply unit 106b is continuous with the space inside the storage tank 106a. The supply unit 106b is provided at a lower end portion of the storage tank 106a. A compressed air is supplied to the storage tank 106a. A lower end of the supply unit 106b is branched into two stage, and the supply unit supplies sand toward the sand introduction hole 2a of the upper flask 2 and the sand introduction hole 3a of the lower flask 3. As a result, sand fills the upper flask 2 and the lower flask 3.

[Control Unit]

As illustrated in FIGS. 1, 5, and 6, a control unit 107 is disposed in the X-axis negative direction of the first position 101, for example. As an example, the control unit 107 includes a programmable logic controller (PLC). The control unit 107 may be a normal computer system including a main storage device such as a central processing unit (CPU), a random access memory (RAM), and a read only memory (ROM), an input device such as a touch panel and a keyboard, an output device such as a display, an auxiliary storage device such as a hard disk, and the like. For example, an operation panel operable by a worker is provided in the control unit 107. The control unit 107 controls movement of configurations of the modeling machine 100 such as movement of the upper flask 2 and the lower flask 3, conveyance of the pattern member 8, rotation of the flask unit 1, and squeezing by the lower squeeze plate 6 and the upper squeeze plate 7.

[Molding Method]

FIG. 9 is a flowchart illustrating an example of a molding method according to the embodiment. The molding method of the present embodiment illustrated in FIG. 9 is started by the control unit 107 based on an instruction of the worker. First, as loading processing (S11), the pattern exchange unit 103 loads the pattern member 8 in the first position 101. In a case where the first mounting unit 45a of the pattern exchange unit 103 is at the pattern preparation position 40b, the worker or the like mounts the pattern member 8 on the first mounting unit 45a of the pattern exchange unit 103. Subsequently, the second arm moving unit 43b causes the second mounting unit 45b positioned at the position facing the first position 101 to retreat from the first position 101 toward the center (X-axis positive direction) of the conveyance base 41. The first arm moving unit 43a causes the first mounting unit 45a having received the new pattern member 8 to retreat from the pattern preparation position 40b toward the center (X-axis negative direction) of the conveyance base 41. Subsequently, the conveyance change unit 46 rotates the conveyance base 41 by 180 degrees to move the pattern member 8 to the position facing the first position 101. At this time, the upper flask 2 and the lower flask 3 are not coupled and are separated from each other. The first mounting unit 45a moves in the X-axis negative direction of the conveyance base 41 by the first arm moving unit 43a. As a result, the first mounting unit 45a is loaded in between the guide members 4 and 4, and the pattern member 8 is loaded in between the upper flask 2 and the lower flask 3.

Subsequently, as coupling processing (S13), the modeling machine 100 couples the upper flask 2 and the lower flask 3. The coupling processing (S13) is a step in which the modeling machine 100 guides the lower flask 3 upward along the guide members 4 and 4 and couples the upper flask 2 and the lower flask 3 via the pattern member 8. The lower flask adjustment cylinders 14 and 14 move the lower flask 3 upward via the lower flask connection units 12 and 12. The lower flask 3 acquires the pattern member 8 from the first mounting unit 45a with the upward movement. The lower flask 3 moves upward by the lower flask connection units 12 and 12 and the lower flask adjustment cylinders 14 and 14 until the upper surface of the pattern member 8 abuts on the lower surface of the upper flask 2. As a result, the upper flask 2 and the lower flask 3 abut on the pattern member 8. Note that, after the pattern member 8 is supported by the lower flask 3, the first mounting unit 45a that does not support the used pattern member 8 is retreated from the first position 101 toward the center (X-axis positive direction) of the conveyance base 41. As a result, it is possible to suppress contact of the first arm unit with the flask unit 1 when the flask unit 1 to be described later rotates.

Subsequently, as first rotation processing (S15), the rotation unit 102 rotates the flask unit 1 such that the flask unit 1 is positioned at the second position 105 from the first position 101. As a result, the molding unit 1A is configured by positioning the flask unit 1 at the second position 105 and being incorporated into the squeeze unit 104.

Subsequently, as fixing processing (S17), the guide fixing unit 70 fixes the guide members 4 and 4 to the cylinder body 63 of the squeeze cylinder 60 by using the wedge members 74 and 74. First, the moving cylinder 65 moves the squeeze cylinder 60 (cylinder body 63) in the X-axis positive direction, and inserts the terminal end portions of the guide members 4 and 4 into the first opening portions 64a and 64a provided to penetrate the attachment member 64 along the X-axis. After the insertion, the guide fixing units 70 and 70 expand the fixing rods 73 and 73 by the fixing cylinders 72 and 72 to move the wedge members 74 and 74 downward. The wedge members 74 and 74 abut on the bodies (groove surfaces of the terminal end portions) of the guide members 4 and 4 and are engaged with the bodies of the guide members 4 and 4. At this time, the upper squeeze plate 7 enters into the upper flask 2 to define the molding space for the cope, and the lower squeeze plate 6 enters the lower flask 3 to define the molding space for the cope.

Subsequently, as supply processing (S19), the sand supply device 106 supplies sand to the upper flask 2 and the lower flask 3. The supply unit 106b of the sand supply device 106 supplies sand to the sand introduction hole 2a of the upper flask 2 and the sand introduction hole 3a of the lower flask 3 to fill the inside of the upper flask 2 and the inside of the lower flask 3 with sand.

Subsequently, as squeeze processing (S21), the squeeze cylinder 60 expands the rod 61 and moves the lower squeeze plate 6 to compress sand in the lower flask 3. At this time, the cylinder body 63 retreats in the X-axis negative direction by a reaction force of an expanding force of the rod 61. The upper squeeze plate 7 moves in the X-axis negative direction in conjunction with the retreating of the cylinder body 63 to compress sand in the upper flask 2. Hereinafter, details will be described with reference to the drawings. FIG. 10 is a plan view illustrating an example of the molding unit during squeezing. As illustrated in FIG. 10, the squeeze cylinder 60 expands the rod 61, and the squeeze pedestal 62 and the lower squeeze plate 6 move in the X-axis positive direction. As a result, the lower squeeze plate 6 squeezes sand in the lower flask 3 by pressing sand in the X-axis positive direction. The attachment member 64 of the cylinder body 63 is moved in the X-axis negative direction via the rod 61 by a reaction force in the X-axis negative direction obtained when the lower squeeze plate 6 of the cylinder body 63 presses sand in the X-axis positive direction. At this time, the attachment member 64 of the cylinder body 63 is fixed to the guide members 4 and 4 via the guide fixing units 70 and 70 in the fixing processing (S17). Thus, the attachment member 64 moves the terminal end portions of the guide members 4 and 4 in the X-axis negative direction via the wedge members 74 and 74. The guide members 4 and 4 move the upper squeeze plate 7 in the X-axis negative direction via the frame 15 in conjunction with the above configuration. The upper squeeze plate 7 squeezes sand in the upper flask 2 by pressing sand in the X-axis negative direction. As described above, the lower squeeze plate 6 and the upper squeeze plate 7 are pressed toward the pattern member 8, and sand stored in the upper flask 2 and sand stored in the lower flask 3 are squeezed to be molded as the cope and the drag.

Subsequently, as retreating processing (S23), the engagement of the guide members 4 and 4 with the wedge members 74 and 74 is released by the shrinking of the fixing rods 73 and 73 due to the driving of the fixing cylinders 72 and 72. The rod 61 contracts. The moving cylinder 65 causes the cylinder body 63 to retreat in the X-axis negative direction. As a result, the lower squeeze plate 6 is unloaded from the lower flask 3, and the incorporation of the squeeze unit 104 is released.

Subsequently, as second rotation processing (S25), the rotation unit 102 rotates the flask unit 1 from the second position 105 toward the first position 101.

Subsequently, as flask removal processing (S27), the upper flask adjustment cylinders 13 and 13 and the lower flask adjustment cylinders 14 and 14 separate the upper flask 2 and the lower flask 3. The pattern exchange unit 103 unloads the pattern member 8. Specifically, the first mounting unit 45a moves in the X-axis negative direction of the conveyance base 41 by the first arm moving unit 43a. The lower flask 3 moves downward by the lower flask connection units 12 and 12 and the lower flask adjustment cylinders 14 and 14, and thus, the pattern member 8 is mounted on the first mounting unit 45a. The first arm moving unit 43a causes the first mounting unit 45a having received the used pattern member 8 to retreat from the first position 101 toward the center (X-axis positive direction) of the conveyance base 41 to unload the pattern member 8. After the pattern member 8 is unloaded, the upper flask adjustment cylinders 13 and 13 and the lower flask adjustment cylinders 14 and 14 mold-assemble the upper flask 2 and the lower flask 3 to remove the mold. Details of flask removal processing after the upper flask 2 and the lower flask 3 are mold-assembled, and details of the flask removal unit 10 will be described later.

Subsequently, as unloading processing (S29), an unloading cylinder (not illustrated) expands to unload the cope and the drag to the outside of the machine (for example, molding line). In a case where the unloading processing (S29) is completed, the molding method using the flask unit 1 and the molding unit 1A is completed. The unloading cylinder may be included in the unloading unit 108.

In the molding unit 1A and the modeling machine 100, the lower squeeze plate 6 enters into the upper and lower flask 23 by the expansion of the rod 61 of the squeeze cylinder 60. Here, since the squeeze cylinder 60 is movably disposed with respect to the upper and lower flask 23, a reaction force obtained via the lower squeeze plate 6 moves in a direction opposite to the squeeze direction of the lower squeeze plate 6. Since the upper squeeze plate 7 is fixed to the cylinder body 63 by the pair of guide members 4 and 4, the upper squeeze plate moves in a direction opposite to the squeeze direction of the lower squeeze plate 6 in accordance with the movement of the squeeze cylinder 60. As a result, the lower squeeze plate 6 and the upper squeeze plate 7 can move to approach each other by using one squeeze cylinder 60. As described above, the molding unit 1A can appropriately perform squeezing by using one squeeze cylinder 60. Thus, initial cost of the molding unit 1A and the modeling machine 100 can be reduced as compared with a molding unit of a modeling machine squeezed by a plurality of actuators.

Each of the pair of guide members 4 and 4 further includes wedge members 74 and 74 that have the distal end portion to which the upper squeeze plate 7 is fixed and the terminal end portion and fix the pair of guide members 4 and 4 to the cylinder body 63. In this case, the molding unit 1A can fix the relative position between the upper squeeze plate 7 and the cylinder body 63 of the squeeze cylinder 60 by using the wedge members 74 and 74.

In the modeling machine 100, the pattern member 8 is loaded in or unloaded from between the upper flask 2 and the lower flask 3 by the conveyance unit 40. The conveyance change unit 46 can rotate the conveyance unit 40 disposed facing the upper and lower flask 23 to a position not facing the upper and lower flask 23, for example. As a result, for example, the new pattern member 8 to be clamped between the upper flask 2 and the lower flask 3 can be smoothly exchanged by mounting the new pattern member 8 on the conveyance unit 40 (second mounting unit 45b) disposed at the position not facing the upper and lower flask 23 (pattern preparation position 40b) and then rotating the new pattern member by the conveyance change unit 46. Accordingly, in the modeling machine 100, even in a case where molding is performed by using a plurality of pattern members, the pattern members 8 can be smoothly exchanged and molded.

In the molding method, the pair of guide members 4 and 4 fixed to the upper squeeze plate 7 is fixed to the cylinder body 63 by the fixing processing (S17). In the squeeze processing (S21), the lower squeeze plate 6 is driven by the squeeze cylinder 60. Since the upper squeeze plate 7 is fixed to the cylinder body 63 by the pair of guide members 4 and 4, the upper squeeze plate moves in a direction opposite to the squeeze direction of the lower squeeze plate 6 in accordance with the movement of the squeeze cylinder 60. In this molding method, similarly to the molding unit 1A and the modeling machine 100 described above, manufacturing cost can be reduced while securing molding accuracy.

[Flask Removal Unit]

The flask removal unit 10 removes the cope and the drag from the upper and lower flask 23. The flask removal unit 10 includes the upper flask 2, the lower flask 3, the guide members 4 and 4, a flask moving unit, an extrusion unit 17, a support unit 18, and a control unit 19. The control unit 19 controls the flask moving unit, the extrusion unit 17, and the support unit 18. The control unit 19 may further control the conveyance unit 40, the rotation unit 102, and the unloading unit 108. The control unit 19 may be included in the control unit 107 or may be separate from the control unit 107.

As described above, the cope is formed inside the upper flask 2. The upper flask 2 has the open upper end and lower end. The drag is formed inside the lower flask 3. The lower flask 3 has the open upper end and lower end. The lower flask 3 can be coupled to the upper flask 2. As described above, the pattern member 8 is disposed between the cope and the drag. At least one of the upper flask 2 and the lower flask 3 is movably connected to the guide members 4 and 4. In the present embodiment, both the upper flask 2 and the lower flask 3 are movably connected to the guide members 4 and 4.

As described above, the upper flask adjustment cylinders 13 and 13 and the lower flask adjustment cylinders 14 and 14 are examples of the flask moving unit. The flask moving unit moves at least one of the upper flask 2 and the lower flask 3 along the guide members 4 and 4. In the present embodiment, the flask moving unit moves the lower flask 3 along the guide members 4 and 4.

The extrusion unit 17 includes an extrusion member. The extrusion member moves relative to the upper and lower flask 23 which are the upper flask 2 and the lower flask 3 coupled to each other. As described above, the upper squeeze plate 7 is an example of an extrusion member. The extrusion unit 17 extrudes the mold from the upper and lower flask 23. The mold is obtained by combining the cope and the drag with each other. The extrusion unit 17 may be a hydraulic cylinder, an air cylinder, or an electric cylinder. For example, the extrusion unit 17 extrudes the mold toward a lower side of the upper and lower flask 23 (Z-axis negative direction).

The support unit 18 includes a support member 18a. The support member 18a moves relative to the upper and lower flask 23. The support member 18a is a plate member that can enter into the lower flask 3 from the opening at the lower end of the lower flask 3. The support member 18a is disposed to clamp the upper and lower flask 23 with the upper squeeze plate 7. The support member 18a enters the lower flask 3 by driving of the support unit 18. The support unit 18 moves the support member 18a together with the upper squeeze plate 7 to support the mold extruded from the upper and lower flask 23 by the extrusion unit 17, and conveys the mold extruded from the upper and lower flask 23 to an unloading position 109. The unloading position 109 is a position where the mold is unloaded. The unloading position 109 may be a space overlapping with the mold to be unloaded. In the present embodiment, the unloading position 109 is at a position below the upper and lower flask 23. The support unit 18 may be a hydraulic cylinder, an air cylinder, or an electric cylinder. For example, the support member 18a supports the mold extruded from the upper and lower flask 23 thereon, and conveys the mold to the unloading position 109 positioned below the upper and lower flask 23. The mold conveyed to the unloading position 109 is unloaded to the outside by the unloading unit 108.

[Flask Removal Method]

Hereinafter, a flask removal method will be described with reference to FIGS. 11A to 11E and 12. Each of FIGS. 11A to 11E is a sectional view illustrating the movement of the upper and lower flask 23 and a mold 9 in the flask removal method according to the embodiment. In each of FIGS. 11A to 11E, the illustration of the extrusion unit 17 and the support unit 18 is omitted except for the upper squeeze plate 7 and the support member 18a. FIG. 12 is a flowchart illustrating an example of the flask removal method according to the embodiment. The flask removal method of the present embodiment illustrated in FIGS. 11A to 11E and 12 is started by the control unit 19 based on an instruction from the worker.

In FIGS. 11A to 11E, the upper and lower flask 23 and the mold 9 are positioned at the first position 101. FIG. 11A is a sectional view illustrating an example of the upper and lower flask and the mold. In the example illustrated in FIG. 11A, the mold 9 and the upper and lower flask 23 from which the pattern member 8 has been unloaded are prepared in the flask removal processing (S27) described above.

First, the mold 9 are extruded from the upper and lower flask 23 (S51). FIG. 11B is a sectional view illustrating a state where the mold is extruded from the upper and lower flask. The mold 9 is extruded by the upper squeeze plate 7 having entered into the upper flask 2 from the opening at the upper end of the upper flask 2. The mold 9 extruded from the upper and lower flask 23 is supported by the support member 18a that moves together with the upper squeeze plate 7. The control unit 19 may control the extrusion unit 17 and the support unit 18 such that the mold 9 is extruded from the upper and lower flask 23 in a state where the mold 9 is clamped between the support member 18a and the upper squeeze plate 7.

Subsequently, the mold 9 extruded from the upper and lower flask 23 is conveyed to the unloading position 109 where the mold 9 is unloaded (S53). At least one of the upper flask 2 and the lower flask 3 is moved to a position where the pattern member 8 can be disposed between the upper flask 2 and the lower flask 3 in a period in which the mold 9 is conveyed to the unloading position 109 (a period in which S53 is performed). FIG. 11C is a sectional view illustrating a state where the mold is conveyed to a conveyance position. In the example illustrated in FIG. 11C, in a period in which the mold 9 is conveyed to the unloading position 109, the lower flask 3 is moved to a position 110 where the pattern member 8 can be disposed between the upper flask 2 and the lower flask 3 (S55).

Subsequently, before a period in which the mold 9 conveyed to the unloading position 109 is unloaded to the outside, the pattern member 8 is loaded between the upper flask 2 and the lower flask 3 (S57). FIG. 11D is a sectional view illustrating a state where the pattern member is conveyed between the upper flask and the lower flask. After the pattern member 8 is loaded in between the upper flask 2 and the lower flask 3, the upper flask 2 and the lower flask 3 are coupled. The pattern member 8 is clamped between the upper flask 2 and the lower flask 3. Details of the loading of the pattern member 8 and the coupling between the upper flask 2 and the lower flask 3 are as described in the loading processing (S11) and the coupling processing (S13).

Subsequently, before a period in which the mold 9 conveyed to the unloading position 109 is unloaded to the outside, the flask unit 1 in which the pattern member 8 is clamped between the upper flask 2 and the lower flask 3 is rotated from the first position 101 to the second position 105 (S59). FIG. 11E is a sectional view illustrating a state where the flask unit is rotated from the first position to the second position. Details of the rotation of the flask unit 1 are as described in the first rotation processing (S15).

In the present embodiment, a trajectory along which the flask unit 1 rotates from the first position 101 to the second position 105 does not pass below the rotation shaft 32 of the rotation unit 102. A virtual circle including the trajectory along which the flask unit 1 rotates from the first position 101 to the second position 105 as a part of a circumference thereof may pass through the unloading position 109. In one example, the trajectory along which the flask unit 1 rotates from the first position 101 to the second position 105 is a trajectory along which a position of the flask unit 1 that is farthest from the rotation shaft 32. In the example illustrated in FIG. 5, the position of the flask unit 1 farthest from the rotation shaft 32 is the lower ends (terminal end portions) of the guide members 4 and 4.

Finally, after a period in which the flask unit 1 clamped by the pattern member 8 rotates from the first position 101 to the second position 105, the mold 9 conveyed to the unloading position 109 is unloaded to the outside (S61). Details of the unloading of the mold 9 is as described in the unloading processing (S29).

[Modifications]

Note that, the above-described embodiment illustrates an example of the modeling machine according to the present disclosure. The modeling machine according to the present disclosure is not limited to the modeling machine 100 according to the embodiment, and the modeling machine 100 according to the embodiment may be modified or applied to other machines without changing the gist described in each claim. For example, the modeling machine 100 may include only the molding unit 1A.

For example, some of the steps of the molding method according to the above-described embodiment may be independent in an order. That is, the steps can be executed in an order different from the described order. The molding method may include the fixing processing (S17) and the squeeze processing (S21), and may not include some or all of other kinds of processing.

The modeling machine 100 may be configured to apply a squeeze force from an upper side to a lower side or from the lower side to the upper side without the rotation unit 102. The molding unit 1A can be applied not only to a flaskless-type modeling machine (flask removal modeling machine) that removes a flask after molding, but also to a modeling machine with a flask, that is, a modeling machine that sends a mold to a casting line without removing a flask after molding, while leaving the mold in the flask.

The guide fixing unit 70 may not include the fixing cylinder 72. At this time, for example, the guide fixing unit 70 may include a fixing rail and a fixing drive unit instead of the fixing cylinder 72. The fixing pedestal 71 supports the fixing rail. The fixing rail extends toward the first opening portion 64a. The fixing drive unit is movably attached to the fixing rail. The fixing drive unit includes the motor and moves on the fixing rail. The wedge member 74 is provided at the lower end of the fixing drive unit. The fixing drive units are driven, and the wedge members 74 and 74 move downward along the fixing rails. Thus, the wedge members 74 and 74 are engaged with the grooves at the terminal end portions of the guide members 4 and 4.

In the above-described embodiment, although it has been described that the lower flask 3 is fixed to the lower flask connection units 12 and 12 and is guided along the guide members 4 and 4 by the lower flask adjustment cylinders 14 and 14, the present disclosure is not limited thereto. In the following description, configurations having the same configurations and functions as the above embodiment are denoted by the same reference signs.

FIG. 13 is a front view illustrating an example of a modeling machine including a slide unit according to a modification. As illustrated in FIG. 13, a modeling machine 100A is different from the modeling machine 100 in that a support structure of the lower flask 3 is different, slide units 90 and 90 are further provided, and others are the same. Hereinafter, differences will be mainly described, and redundant description will be omitted.

The modeling machine 100A further includes lower flask support units 80 and 80 and the slide units 90 and 90. At the first position 101, the lower flask 3 is supported by the lower flask support units 80 and 80. The lower flask 3 has an abutment unit 91 at an upper portion of a side surface thereof.

The lower flask support units 80 and 80 are fixed to the lower flask connection units 12 and 12. Thus, the lower flask support units 80 and 80 are movable in the up-down direction by the lower flask adjustment cylinders 14 and 14. The lower flask support unit 80 includes, for example, a side wall 80a extending along the XZ plane and a bottom portion 80b extending along the XY plane at a lower end portion of the side wall 80a. The lower flask support units 80 and 80 are separated from each other in the Y direction to form a second opening portion 80c. The lower flask support unit 80 defines an accommodation space 80d capable of accommodating the lower flask 3.

A support abutment unit 81 protruding toward the accommodation space 80d is provided inside the side wall 80a at an upper end portion of the lower flask support unit 80. The support abutment unit 81 moves upward by the lower flask adjustment cylinder 14 to abut on the abutment unit 91 of the lower flask 3 from below, and can support the lower flask 3.

The slide units 90 and 90 slide the lower flask 3 separated from the upper flask 2. That is, the slide units 90 and 90 slide the lower flask 3 from between the guide members 4 and 4. The slide unit 90 is, for example, a rail extending along the X direction. For example, the slide units 90 and 90 slide the lower flask 3 toward the worker positioned in the X-axis negative direction at the first position 101. The slide unit 90 can protrude from the second opening portion 80c of the lower flask support unit 80 into the accommodation space 80d of the lower flask support unit 80. The slide unit 90 protrudes into the accommodation space 80d, and thus, the lower flask 3 can be supported while being separated from the lower flask support unit 80. The slide units 90 and 90 support the lower flask 3 and then move the lower flask 3 in the X-axis negative direction.

For example, after the flask removal processing (S27) and before the unloading processing (S29) and processing of newly inserting the first mounting unit 45a between the upper flask 2 and the lower flask 3, the lower flask 3 may be unloaded by the slide units 90 and 90 as flask removal processing. The flask removal processing can be performed by the worker. In the flask removal processing (S27), the lower flask support units 80 and 80 move downward by the lower flask adjustment cylinders 14 and 14. When the lower flask support units 80 and 80 move to predetermined positions, the slide units 90 and 90 are inserted relatively upward from between the lower flask support units 80 and 80. As a result, the lower flask 3 supported by the support abutment units 81 and 81 of the lower flask support units 80 and 80 is supported by the slide units 90 and 90. After the lower flask 3 is supported by the slide units 90 and 90, the flask removal processing is executed, and the lower flask 3 can be slid in the X-axis negative direction along the slide units 90 and 90. In this manner, the slide units 90 and 90 can slide the lower flask 3 from between the guide members 4 and 4. Accordingly, the worker can easily access the lower flask 3 without interfering with the guide members 4 and 4 and the upper flask 2. As a result, workability in a case where the worker installs a core in the lower flask 3 is improved.

The guide members 4 and 4 may not be disposed at the positions symmetrical with respect to the center lines passing through the centers of the upper flask 2 and the lower flask 3. FIG. 14A is a sectional view illustrating a part of a molding unit according to a modification. FIG. 14A is a sectional view taken along a line at the same position as line XII-XII in FIG. 7 in a molding unit 1B according to the modification, and some members are omitted. As illustrated in FIG. 14A, the molding unit 1B in a modeling machine 100B is different from the molding unit 1A in the modeling machine 100 in that guide members 4B and 4B with respect to the upper flask 2 are collectively disposed on one side wall of the upper flask 2, and others are the same. Hereinafter, differences will be mainly described, and redundant description will be omitted.

At the second position 105, the guide members 4B and 4B of the molding unit 1B extend along the XY plane, for example. The upper flask connection units 11B and 11B are each connected to one side wall extending along the XZ plane of the upper flask 2. The upper flask connection units 11B and 11B are disposed at positions symmetrical with respect to a center of the side wall of the upper flask 2. The upper flask connection unit 11B is movably connected to the guide member 4B. The upper flask 2 is supported by the guide members 4B and 4B and the upper flask connection units 11B and 11B provided on the upper flask 2. Although not illustrated in FIG. 14A, the lower flask 3 is supported by the guide members 4B and 4B provided on one side wall of the lower flask 3 and the lower flask connection unit. The lower flask 3 moves by a driving force of the lower flask adjustment cylinders 14B and 14B.

As in the above-described embodiment, since the squeeze cylinder 60 in the molding unit 1B is also movably disposed with respect to the upper and lower flask 23 as in the above-described embodiment, the molding unit 1B can appropriately perform squeezing by using one squeeze cylinder. As compared with the molding unit of the modeling machine of the related art, the molding unit 1B and the modeling machine 100B can reduce the manufacturing cost of the mold including the initial cost and the like. Since the molding unit 1B can save a space as compared with a configuration in which a plurality of guide members are disposed independently, for example, the worker can easily access each configuration of the molding unit 1B before and after molding, and as a result, workability is improved. In the molding unit 1B, since the guide members 4B and 4B are collectively disposed on one side wall of the upper and lower flask 23, a space facing the other side wall of the upper and lower flask 23 can be saved. Note that, the molding unit 1B is not limited to the configuration including the two guide members 4B and 4B, and may include three or more guide members 4B.

The molding unit and the modeling machine may include one guide member instead of the guide members 4 and 4. FIG. 14B is a sectional view illustrating a part of a molding unit according to a modification. FIG. 14B is a sectional view taken along a line at the same position as line XII-XII in FIG. 7 in a molding unit 1C according to the modification, and some members are omitted. As illustrated in FIG. 14B, the molding unit 1C in a modeling machine 100C is different from the molding unit 1A in the modeling machine 100 in the position and the number of guide members with respect to the upper flask 2, and others are the same. Hereinafter, differences will be mainly described, and redundant description will be omitted.

The molding unit 1C includes one guide member 4C and one upper flask connection unit 11C. The guide member 4C extends, for example, along the XY plane. The upper flask connection unit 11C is connected to one side wall extending along the XZ plane of the upper flask 2. The upper flask connection unit 11C is disposed to be positioned at the center of the side wall of the upper flask 2 as viewed from the X direction. The upper flask connection unit 11C is movably connected to the guide member 4C. The upper flask 2 is supported by the guide member 4C and the upper flask connection unit 11C provided on the upper flask 2. Although not illustrated in FIG. 14B, the lower flask 3 is supported by the guide member 4C provided on one side wall of the lower flask 3 and the lower flask connection unit. The lower flask 3 moves by a driving force of a lower flask adjustment cylinder 14C.

As in the above-described embodiment, the squeeze cylinder 60 in the molding unit 1C is movably disposed with respect to the upper and lower flask 23. Accordingly, the molding unit 1C can appropriately perform squeezing by using one squeeze cylinder. Thus, as compared with the molding unit of the modeling machine of the related art, the molding unit 1C and the modeling machine 100C can reduce the manufacturing cost of the mold including the initial cost and the like. Since the molding unit 1C can save a space as compared with a configuration in which a plurality of guide members are disposed independently, for example, the worker can easily access each configuration of the molding unit 1C before and after molding, and as a result, workability is improved.

Since only one guide member 4C is disposed in the molding unit 1C, for example, the space can be saved as compared with a configuration in which a plurality of guide members are disposed in the molding units 1A and 1B and a molding unit 1D to be described later. As compared with the molding units 1A and 1B, the molding unit 1D to be described later, the modeling machines 100A and 100B, and a modeling machine 100D to be described later, since the molding unit 1C and the modeling machine 100C can reduce the number of guide members, the manufacturing cost including the initial cost and the like can be further reduced.

The guide members 4 and 4 may not be disposed at symmetrical positions with a surface along the XZ plane interposed therebetween in the upper flask 2 and the lower flask 3 at the second position 105. FIG. 14C is a sectional view illustrating a part of a molding unit according to a modification. FIG. 14C is a sectional view taken along a line at the same position as line XII-XII in FIG. 7 in the molding unit 1D according to the modification, and some members are omitted. As illustrated in FIG. 14C, the molding unit 1D in the modeling machine 100D is different from the molding unit 1A in the modeling machine 100 in that guide members 4D and 4D with respect to the upper flask 2 at the second position 105 are not disposed at plane-symmetrical positions with the plane along the XZ plane interposed therebetween and are disposed at positions point-symmetrical with respect to the center of the upper flask 2 in the YZ plane, and others are the same. Hereinafter, differences will be mainly described, and redundant description will be omitted.

At the second position 105, the guide members 4D and 4D of the molding unit 1D extend along the XY plane, for example. Upper flask connection units 11D and 11D are connected to two side walls extending along the XZ plane of the upper flask 2. The upper flask connection units 11D and 11D are not disposed at plane-symmetrical positions with the plane along the XZ plane interposed therebetween, but are disposed at positions point-symmetrical with respect to the center of the upper flask 2 on the YZ plane. The upper flask connection unit 11D is movably connected to the guide member 4D. The upper flask 2 is supported by the guide members 4D and 4D and the upper flask connection units 11D and 11D provided on the upper flask 2. Although not illustrated in FIG. 14C, the lower flask 3 is supported by the guide members 4D and 4D and the lower flask connection unit provided on two side walls of the lower flask 3. The lower flask 3 moves by a driving force of the lower flask adjustment cylinders 14D and 14D.

As in the above-described embodiment, since the squeeze cylinder 60 in the molding unit 1D is also movably disposed with respect to the upper and lower flask 23, the molding unit 1D can appropriately perform squeezing by using one squeeze cylinder. As compared with the molding unit of the modeling machine of the related art, the molding unit 1D and the modeling machine 100D can also reduce the manufacturing cost of the mold including the initial cost and the like. Since the molding unit 1D can save a space as compared with a configuration in which a plurality of guide members are disposed independently, for example, the worker can easily access each configuration of the molding unit 1D before and after molding, and workability is improved. Since the guide members 4D and 4D are disposed at different positions in the Z direction in the molding unit 1D at the second position 105, other configurations of the molding unit 1D or the modeling machine 100D are disposed at different positions, and a degree of freedom in design is improved. Note that, the molding unit 1D is not limited to the configuration including the two guide members 4D and 4D, and may include three or more guide members 4D.

Although various exemplary embodiments have been described above, the present disclosure is not limited to the above embodiments, and various omissions, substitutions, and changes may be made.

Only the upper flask 2 may be movably connected to the guide members 4 and 4, and only the lower flask 3 may be movably connected to the guide members. The flask moving unit may move the upper flask 2 along the guide members 4 and 4, or may move both the upper flask 2 and the lower flask 3 along the guide members 4 and 4. In a period in which the mold 9 is conveyed to the unloading position 109, the upper flask 2 may be moved to a position where the pattern member 8 can be disposed between the upper flask 2 and the lower flask 3, or both the upper flask 2 and the lower flask 3 may be moved. In the loading (S57) of the pattern member 8, the pattern member 8 may be loaded in between the upper flask 2 and the lower flask 3 in a period in which the mold 9 conveyed to the unloading position 109 is unloaded to the outside. In the rotation (S59) of the flask unit 1, in a period in which the mold 9 conveyed to the unloading position 109 is unloaded to the outside, the flask unit 1 in which the pattern member 8 is clamped between the upper flask 2 and the lower flask 3 may be rotated from the first position 101 to the second position 105. In the unloading (S61) of the mold 9, in a period in which the flask unit 1 clamped by the pattern member 8 rotates from the first position 101 to the second position 105, the mold 9 conveyed to the unloading position 109 may be unloaded to the outside. The guide members 4 and 4 may include a plurality of relatively movable members. For example, the guide member 4 may include a flask guide member having a cylindrical shape and a squeeze guide member movably disposed inside a cylinder of the flask guide member. The flask guide member is fixed to the attachment member 64, and the squeeze guide member is fixed to the frame 15.

[Modes Included in Present Disclosure]

The present disclosure includes the following modes.

(Clause 1)

Provided is a flask removal unit that removes a cope and a drag between which a pattern member is disposed from an upper and lower flask.

The flask removal unit includes an upper flask having the cope formed inside and having open upper end and lower end, an lower flask having the drag formed inside and having open upper end and lower end, a guide member to which at least one of the upper flask and the lower flask is movably connected, a flask moving unit configured to move at least one of the upper flask and the lower flask along the guide member, an extrusion unit including an extrusion member configured to relatively move with respect to the upper and lower flask obtained by coupling the upper flask and the lower flask to each other, and configured to extrude, from the upper and lower flask, a mold obtained by combining the cope and the drag with each other, a support unit including a support member configured to relatively move to the upper and lower flask, configured to move the support member together with the extrusion member to support the mold extruded from the upper and lower flask by the extrusion unit, and configured to convey the mold extruded from the upper and lower flask to an unloading position where the mold is unloaded, and a control unit configured to control the flask moving unit, the extrusion unit, and the support unit.

The control unit is configured to perform control such that at least one of the upper flask and the lower flask is moved to a position where the pattern member is able to be disposed between the upper flask and the lower flask in a period in which the support unit conveys the mold to the unloading position.

According to the flask removal unit, in the period in which the support unit conveys the mold, an interval between the upper flask and the lower flask is widened until the pattern member can be disposed.

Accordingly, as compared with the flask removal unit that widens the interval between the upper flask and the lower flask after the mold is conveyed, in the flask removal unit, the interval between the upper flask and the lower flask is widened quickly.

As a result, since the pattern member can be disposed quickly between the upper flask and the lower flask, the flask removal unit can shorten a cycle time of the removing of the flask.

(Clause 2)

In the flask removal unit according to Clause 1, the lower flask is movably connected to the guide member, the flask moving unit is configured to move the lower flask along the guide member, the unloading position is at a position below the upper and lower flask, and the control unit is configured to perform control such that the lower flask is moved along the guide member to a position where the pattern member is able to be disposed between the upper flask and the lower flask in a period in which the support unit conveys the mold to the unloading position.

In this flask removal unit, since the lower flask moves downward in a period in which the support unit conveys the mold downward, the pattern member can be disposed quickly between the upper flask and the lower flask.

Accordingly, the cycle time of the removing of the flask is shortened.

(Clause 3)

Provided is a modeling machine including the flask removal unit according to Clause 1 or 2 further includes a conveyance unit configured to load and unload the pattern member in and from between the upper flask and the lower flask, a rotation unit configured to rotate a flask unit including the upper and lower flask and the guide member between a first position where flask removal is performed and a second position where squeezing is performed, and an unloading unit configured to unload the mold conveyed to the unloading position to an outside.

The control unit is configured to control the conveyance unit, the rotation unit, and the unloading unit, and perform control such that the flask unit in which the pattern member is loaded in between the upper flask and the lower flask and the pattern member is clamped between the upper flask and the lower flask rotates from the first position to the second position in a period in which the mold conveyed to the unloading position is conveyed to the outside or before the period in which the mold is conveyed to the outside.

According to this modeling machine, the flask unit is rotated from the first position to the second position before the period in which the mold is unloaded to the outside or the period in which the mold is unloaded to the outside.

Accordingly, the modeling machine can shorten the cycle time of the molding of the mold and the removing of the flask as compared with the modeling machine that rotates the flask unit after the mold is unloaded to the outside.

(Clause 4)

In the modeling machine according to Clause 3, a trajectory along which the flask unit rotates from the first position to the second position does not pass below a rotation shaft of the rotation unit.

In this modeling machine, as compared with the modeling machine in which the trajectory along which the flask unit rotates from the first position to the second position passes below the rotation shaft of the rotation unit, the flask unit and the mold conveyed to the unloading position hardly interfere with each other.

Accordingly, this modeling machine can be be downsized as compared with the modeling machine in which the trajectory along which the flask unit rotates from the first position to the second position passes below the rotation shaft of the rotation unit.

(Clause 5)

In the modeling machine according to Clause 3 or 4, a virtual circle including the trajectory along which the flask unit rotates from the first position to the second position, as a part of a circumference of the circle passes through the unloading position.

In a case where the trajectory along which the flask unit rotates from the first position to the second position does not pass below the rotation shaft of the rotation unit, the flask unit and the mold conveyed to the unloading position hardly interfere with each other.

Accordingly, in this modeling machine, even though the virtual circle including the trajectory along which the flask unit rotates from the first position to the second position as a part of a circumference thereof passes through the unloading position, the flask unit and the mold conveyed to the unloading position do not interfere with each other.

As a result, the modeling machine can be downsized as compared with the modeling machine in which the virtual circle including the trajectory along which the flask unit rotates from the first position to the second position as a part of a circumference thereof does not pass through the unloading position.

(Clause 6)

In the modeling machine according to any one of Clauses 3 to 5, the control unit is configured to unload the mold conveyed to the unloading position to an outside in a period in which the flask unit in which the pattern member is clamped rotates from the first position to the second position, or after the period in which the flask unit rotates from the first position to the second position.

According to this modeling machine, since the mold conveyed to the unloading position is unloaded to the outside in the period in which squeezing is performed at the second position, it is possible to shorten the cycle time of the molding of the mold and the removing from the mold as compared with the modeling machine that rotates the flask unit after the mold is unloaded to the outside.

(Clause 7)

Provided is a flask removal method for removing a cope and a drag between which a pattern member is disposed from an upper and lower flask.

The flask removal method includes extruding a mold obtained by combining the cope and the drag with each other from an upper and lower flask obtained by coupling an upper flask having the cope formed inside and having open upper end and lower end and an lower flask having the drag formed inside and having open upper end and lower end, conveying the mold extruded from the upper and lower flask to an unloading position where the mold is unloaded, and moving at least one of the upper flask and the lower flask to a position where the pattern member is able to be disposed between the upper flask and the lower flask.

The moving of the at least one of the upper flask and the lower flask is performed in a period which the conveying of the mold to the unloading position is performed.

According to this flask removal method, the cycle time of the removing of the flask can be shortened similarly to the flask removal unit.

The flask removal method according to Clause 7 may be performed in the flask removal unit according to Clause 1 or 2, or may be performed in the modeling machine according to any one of Clauses 3 to 6.

FLASK REMOVAL UNIT, MODELING MACHINE, AND FLASK REMOVAL METHOD

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