• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Provided are a quality management device and a die casting forming machine, which are adapted to check the quality with respect to the voids amount of a die cast product being cast according to a PF die casting process. A quality management device (3) performs the quality management for the die cast product formed according to the non-porous die casting method in which oxygen is supplied into a cavity (Ca) and an injection sleeve (27) connected to the cavity (Ca) and in this state a melt in the injection sleeve (27) is discharged into the cavity (Ca). The quality management apparatus (3) further includes a vacuum sensor that detects the air pressure in the cavity Ca, and a controller (70) that performs a good / erroneous judgment on the quality of the die-cast product with respect to the voids amount based on the air pressure, which is detected by the vacuum sensor during filling.
    公开号:CH706068B1
    申请号:CH01011/13
    申请日:2011-11-15
    公开日:2016-10-14
    发明作者:Tomioka Satoshi；Aida Satoru
    申请人:Toshiba Machine Co Ltd；
    IPC主号:
    专利说明:

    Technical area
    [0001] The present invention relates to a quality management apparatus and a die-casting forming machine designed to check the quality of a die-cast product cast by a non-porous (PF) die-casting process.
    State of the art
    In the art, a die casting method is known, which is referred to as "PF die casting". In this die-casting process, the air in a cavity or cavity, a channel and an injection sleeve is replaced by an active gas (generally oxygen) prior to filling a melt (metal in the liquid state). As a result, due to an oxidizing reaction between the oxygen and the melt, the cavity enters a decompressed state to form a die-cast product having few pores (voids) (see Patent Literature 1).
    Further, as a method of measuring the voids amount in a die-cast product, a method using CT X-ray analysis is known (see Patent Literature 2).Bibliographypatent literaturePatent Literature 1: Japanese Patent Publication No. 45-10481 B2Patent Literature 2: Japanese Patent Publication No. 2009-183958A
    Brief description of the invention
    Technical problem
    The measurement of the voids amount by CT X-ray analysis has the disadvantages that the equipment is expensive, the on-line use requires installation space therefor, the inspection time is longer than the pouring cycle time, and so on.
    Accordingly, there is provided a quality management apparatus and a die casting forming machine capable of adequately checking the quality with respect to the amount of voids in a die-cast product being cast by the PF die casting method.
    the solution of the problem
    In a quality management device according to the invention is a quality management device for a die-cast product, which is formed by a pore-free die casting process, which feeds an active gas into a cavity and into an injection sleeve, which is connected to the cavity, and in this state, a melt located in the injection sleeve, into the cavity, the device comprising a vacuum sensor detecting the air pressure in the cavity and a control device providing a "good / erroneous" judgment of the quality of the die cast product in relation to the amount of voids based on the air pressure detected by the vacuum sensor during filling.
    The control device judges that a fault exists when a lowest air pressure or a mean degree of vacuum, which the vacuum sensor detects when filling, is higher than a predetermined threshold.
    Alternatively, the control device judges that there is an error when a time for which the air pressure detected by the vacuum sensor when filling is less than a predetermined reference pressure which is at most the atmospheric pressure is shorter than a predetermined target time.
    The vacuum sensor is preferably connected to a vent channel which vents the cavity.
    The quality management device further preferably has a check valve or check valve, which allows a flow from the venting channel to the outside at atmospheric pressure and prevents flow from the outside to the venting channel.
    The quality management device preferably further comprises a reporting element which reports the results of the judgment by the control device until the beginning of the next cycle.
    Preferably, the system is further equipped with a sorting device that sorts the die-cast products according to the results of the judgment by the control device.
    A die-casting molding machine according to the present invention comprises: a clamping device that holds a mold configuring a cavity, an injection device that is arranged, a melt that is located in an injection sleeve, which is connected to the cavity to deliver into the cavity, an active gas supply unit adapted to supply active gas to the injection sleeve, a vacuum sensor adapted to detect an air pressure in the cavity, and a control device having a "good / faulty" - Assessment of the quality of the die cast product in relation to the amount of voids based on the air pressure detected by the vacuum sensor during filling or injection.
    The control device of the die-casting molding machine is preferably configured to control the active gas supply unit based on the air pressure detected by the vacuum sensor.
    The control device preferably increases in the next cycle, the supplied from the Aktivgaszufuhreinheit active gas when a lowest air pressure detected by the vacuum sensor during filling, is higher than a predetermined threshold.
    The control device preferably interrupts the continuation of a cycle when the air pressure detected by the vacuum sensor during filling is higher than a predetermined threshold and predetermined cycle continuation conditions are not met, the following being among the cycle continuation conditions: increasing the supplied active gas prior to current cycle and not exceeding a predetermined level in the degree of this increase or increasing the supply amount of active gas in the current cycle with respect to the previous cycle and reducing the detected by the vacuum sensor during filling air pressure in the current cycle compared to the previous cycle.
    Advantageous effects of the invention
    According to the present invention, a die-cast product which is cast according to the PF die casting method can be adequately checked.
    Brief description of the drawings
    [0019]<Tb> FIG. 1: <SEP> Cross-sectional view showing the configuration of a die casting molding machine according to a first embodiment of the present invention.<Tb> FIG. 2: <SEP> Cross-sectional view showing a melt-pouring condition of the die-casting molding machine of FIG. 1.<Tb> FIG. 3: <SEP> FIGS. 3 (a) and 3 (b) are diagrams showing details of a vacuum degree sensor incorporated in the die-cast molding machine of FIG. 1.<Tb> FIG. 4 is a block diagram showing the configuration of a quality management apparatus of the die-cast molding machine of FIG. 1.<Tb> FIG. 5: A flowchart showing a molding cycle of the die-casting molding machine of FIG. 1.<Tb> FIG. FIG. 6 is a graph showing changes in the filling speed, the filling pressure and the degree of vacuum in the mold in the die-casting forming machine of FIG. 1 over time. FIG.<Tb> FIG. 7: <SEP> Diagram showing relations between an oxygen supply amount and the degree of vacuum in the mold and the gas amount of the die-cast product in the die-cast molding machine of FIG. 1.<Tb> FIG. 8: <SEP> Flowchart for Quality Management in the Die Casting Forming Machine of FIG. 1.<Tb> FIG. 9: <SEP> Schedule to adjust the amount of oxygen in a modification.<Tb> FIG. 10: <SEP> diagram explaining the principle of a second embodiment.<Tb> FIG. 11: <SEP> Another diagram explaining the principle of the second embodiment.
    Description of embodiments
    (First Embodiment)
    Fig. 1 is a cross-sectional view showing the configuration of a die-casting molding machine 1 according to a first embodiment of the present invention. Fig. 2 is a cross-sectional view showing a melt-pouring condition of the die-cast molding machine.
    The die-casting molding machine 1 includes: a clamping device 5 that opens / closes and clamps a fixed die 103 and a movable die 105 (both sometimes collectively referred to as "die 101" hereinafter), an injector 7, which fills a melt ML (FIG. 2) into a cavity Ca formed in the mold 101 clamped by the clamping device 5, an ejecting device 9 which ejects a die-cast product formed by solidification of the melt ML, an oxygen supply unit 11 feeds the cavity Ca. active gas (oxygen in the present embodiment), a mold vacuum degree measuring unit 50 which measures the degree of vacuum in the cavity Ca (mold vacuum degree), and a control device 70.
    The die-casting molding machine 1 further includes a quality management device 3 for managing the quality of the die-cast product. The mold vacuum degree measuring unit 50 and the control device 70 also function as components of the quality management device 3.
    The clamping device 5 comprises: a fixed mold plate 15 which holds the fixed mold 103, a movable mold plate 17 which holds the movable mold 105, and a drive unit, not shown, which the movable mold plate 17 in a direction to open / Close the mold can drive. The drive unit is configured for example by a hydraulic cylinder or electric motor or a combination thereof.
    The injection device 7 has a sleeve 27, which is connected to the cavity Ca via a channel or sprue Rn, a filling piston 29, which can move in the sleeve 27, and a filling cylinder unit, not shown, which or injection piston 29 drives.
    In the sleeve 27, a pouring opening 27a, which is supplied with melt from a ladle 33 (Fig. 2), and an oxygen supply port 27b, which - is different than the pouring opening 27a - on the side of the fixed mold plate 15 and through which oxygen is supplied, opened.
    The ejecting device 9 has a plurality of Auswerfstifte 35, which abut the molded product formed by the solidifying melt ML, a Auswerfplatte 37 to which the plurality of Auswerfstifte 35 are attached Auswerfstangen 39, which are attached to the Auswerfplatte 37, and an ejection cylinder unit 40 which drives the ejection bars 39.
    The oxygen supply unit 11 has a pipe 41 connected to the oxygen supply port 27b, a valve 43 connected to the pipe 41, a pipe 42 connected to the valve 43, and an oxygen cylinder 44 (supply source for active gas) connected to the pipe 42.
    By opening the valve 43, the sleeve or sleeve 27 oxygen is supplied from the oxygen cylinder 44, while the oxygen supply is interrupted by closing the valve 43. The valve 43 is configured, for example, by a type of air-operated valve to prevent the generation of sparks.
    It should be noted that the amount of oxygen supplied to the sleeve 27 is controlled by, for example, the opening degree, the opening duration, the duty ratio of the opening / closing of the valve 43, and so forth. The regulation of the amount of oxygen can be done by control without feedback or by regulation based on a flow meter, not shown.
    The oxygen cylinder 44 may be one having a pressure that is kept constant or one where the pressure drops along with the oxygen supply. Note that, even if the pressure of the oxygen cylinder 44 drops, the oxygen supply amount is kept constant by adjusting the opening degree, etc. of the valve 43.
    Fig. 3 (a) is a cross-sectional view showing details of the mold vacuum degree measuring unit 50 and corresponds to a partially enlarged view of Fig. 1. Fig. 3 (b) is a diagram showing the fixed die 103 from the side of the movable die 105 in an area shown in Fig. 3 (a).
    In the mold 101, a vent passage 60 is configured to vent the interior of the cavity Ca. The vent passage 60 is configured, for example, by a serrated gap (cooling passage 60c) formed between the fixed die 103 and the movable die 105, and a vent passage 60a connected to the cooling passage 60c and formed in the fixed die 103.
    The mold vacuum degree measuring unit 50 includes a vacuum sensor 51 and a check valve 52 which are connected to the vent passage 60.
    In particular, a tube 53 is connected to a vent opening 60b of the venting channel 60. The pipe 53 branches into a pipe 53a and a pipe 53b. The vacuum sensor 51 is connected to the pipe 53b, while the check valve 52 is connected to the pipe 53a.
    The vacuum sensor 51 is, for example, an electrostatic capacity or vibration type pressure sensor which generates an electrical signal having a signal level corresponding to the pressure within the cavity Ca (more specifically, the vent passage 60 and, more specifically, the tube 53b). corresponds, outputs via a line 71 to the control device 70.
    The check valve 52 is disposed between the pipe 53 a and the pipe 54. A terminal end 54a of the tube 54 is open to the atmosphere. Further, the check valve 52 allows flow from the cavity Ca (more specifically, from the vent passage 60 and, more specifically, from the tube 53a) to the outside (strictly speaking to the tube 54) while inhibiting the flow in the reverse direction.
    Accordingly, when a negative pressure prevails in the cavity Ca, there is a state in which the inside area of the cavity Ca is not opened to the atmosphere, so that the degree of vacuum is maintained. On the other hand, when the inside area of the cavity Ca is at least atmospheric pressure, the gas in the cavity Ca is drained via the tube 54.
    FIG. 4 is a block diagram showing the configuration of the quality management apparatus 3.
    The quality management device 3 has, besides the above-mentioned vacuum sensor 51 and the above-explained control device 70, a message notification unit 72 to the user and a sorting device 74 that sorts die-cast products.
    The control device 70 is configured with, for example, a CPU, ROM, RAM, and an external storage unit (not separately shown). The CPU has programs stored in the ROM and the external storage unit. For this reason, a quality judging part 70a and a management control part 70b are configured.
    The quality judging part 70a judges the quality of the die-cast products based on the pressure detected by the vacuum sensor 51 as good / defective. The management control part 70b performs the processing necessary for the notification unit 72 and the sorter 74 to perform operations corresponding to results of the judgment.
    Although the control device 70 is not shown separately, but controls the clamping device 5, the injector 7, the ejector 9, the oxygen supply unit 11, etc. That is, the control device 70 also controls the opening / closing of the mold, the Clamping, filling, ejecting and supplying oxygen in the die-casting machine.
    The reporting unit 72 is, for example, a display unit or a sound emitting device. The display unit is one that displays images, such as a liquid crystal display, or one that displays lights, flash, or power off messages, such as an LED. The sound emitting device is one that outputs a sound, such as a speaker. For example, if a die-cast product is formed that is judged to be "defective," the reporting unit 72 reports this fact.
    The sorter 74 is configured, for example, by a product unloading unit having a gripping member which grips the die-cast product and an arm which moves the gripping member. It should be noted that the sorter 74 transports the die cast products removed from the mold 101 to separate good and defective product destinations. The sorting takes place accordingly.
    FIG. 5 is a flowchart showing the molding cycle routine that the die-cast forming machine 1 performs. The processing is repeated in a predetermined period.
    At step S10, the control device 70 controls the clamp 5 to close and clamp the mold. Further, it controls the injector 7 so as to raise the filling piston 29 to the position for closing the pouring opening 27a (see FIG. 1).
    At step S10, the control device 70 controls the oxygen supply unit 11 so that the valve 43 is opened and oxygen is supplied from the oxygen cylinder 44 to the oxygen supply port 27b. Thereby, the gas in the sleeve 27, the channel Rn and the cavity Ca is replaced by oxygen.
    It should be noted that the amount of oxygen supplied is a fixed amount determined in advance for each mold 101, so that die-cast products having a consistent quality with respect to the amount of voids are obtained. When oxygen is supplied in the predetermined amount, the valve 43 is closed. The timing for closing the valve 43 may be set appropriately before the step S14.
    At step S12, the injection device 7 is controlled so that the filling piston 29 is pulled back to the position in which it does not close the pouring opening 27a.
    At step S13, the control device 70 controls a non-illustrated melt casting apparatus so that the melt is poured into the pouring spout 27a with the ladle 33 (see FIG. 2).
    At step S14, the control device 70 controls the injector 7 so that the filling piston 29 advances and discharges the melt in the sleeve 27 into the cavity Ca. That is, the filling is performed.
    In particular, the control device 70 controls, for example, first the injection device 7 so that a filling operation is carried out at low speed, in which the filling piston 29 advances relatively slowly in order to prevent entrainment of gas through the melt. When the filling piston 29 reaches a predetermined speed change position or another predetermined speed change condition is satisfied, the control device 70 controls the injector 7 so that a high-speed filling operation is performed in which the filling piston 29 advances at a relatively high speed to rapidly feed the melt into the cavity Ca. to fill.
    Further, in step S14, after the high-speed filling operation, an increasing step for increasing the pressure of the melt in the cavity Ca is performed by applying pressure to the melt through the filling piston 29. For example, the control device 70 switches the control of the injector 7 from the speed control to the pressure control when the filling piston 29 reaches a predetermined position, the filling pressure reaches a predetermined value, or another predetermined condition for the increase start is satisfied.
    Further, when the pressure of the melt reaches a predetermined casting pressure, a pressure holding step for holding the pressure of the melt is performed on the casting pressure by continuing to apply pressure to the melt via the filling piston 29. While the pressure is maintained, the melt cools and solidifies.
    Further, at step S14, the controller 70 obtains data on the pressure in the cavity Ca during filling based on the detection signal of the vacuum sensor 51. Thereby, as explained later with reference to FIG. 8, the quality management of the formed die-cast product becomes possible.
    At step S15, the control device 70 controls the clamp 5 to open the mold and the ejector 9 to eject the die cast product from the movable mold 105 through the ejection pins 35.
    Fig. 6 is a graph showing changes in the filling speed (Fig. 6 (c)), the filling pressure (Fig. 6 (b)) and the degree of vacuum in the mold (Fig. 6 (a)) at the time of filling and refilling the die-cast forming machine 1 over time (step S14).
    As shown in Fig. 6 (c), the filling speed V is small in a predetermined period of time from the start of filling and is changed to high at a high-speed starting point D. Thereafter, the melt is substantially filled in the cavity Ca, so that the filling piston 29 is subjected to reaction force from the melt, or a deceleration control is executed, whereby the filling speed V drops and the filling piston 29 finally stops.
    Further, as shown in Fig. 6 (b), the filling pressure P is a relatively low pressure PL in the low-speed filling operation, while in the high-speed filling operation, it is a pressure PH higher than the pressure PL. When the melt has been substantially filled in the cavity Ca, the filling pressure P increases and reaches the casting pressure Pmax, which is then held.
    Further, as shown in Fig. 6 (a), the mold vacuum degree VA (air pressure in the mold, i.e., detection value of the vacuum sensor 51) approximately corresponds to the atmospheric pressure in the low-speed filling operation, and is maintained at a predetermined value. Further, in the high-speed filling operation, due to the progressing reaction between melt and oxygen, the pressure in the cavity Ca decreases, so that the air pressure drops. Thereafter, when the cavity Ca is substantially filled with melt, the air pressure in the cavity Ca is again approximately at atmospheric pressure.
    As described above, the air pressure in the mold decreases in the course of the high-speed filling operation. It should be noted that the mold vacuum degree VA when the atmospheric pressure becomes lowest will be referred to as "vacuum degree VAMIN with the lowest pressure" in the following description.
    Fig. 7 shows the relationships between the oxygen supply amount (step S10), the vacuum degree VAMIN with the lowest pressure and the amount of gas contained in the die-cast product.
    Fig. 7 is based on the actual measured value in a mold. The amount of gas is determined by selecting a sample under the die cast products and measuring it with a gas flow meter. It should be noted that the gas amount is a parameter having a strong correlation with the voids amount. A large amount of gas represents poor quality in relation to the amount of voids.
    From Fig. 7 it can be seen that the amount of gas decreases as the oxygen supply increases, and a die-cast product of higher quality is formed. It should be noted that the decrease in the amount of gas in relation to an increase in the oxygen supply weakens when the oxygen supply exceeds a predetermined amount. Accordingly, it can be seen that an excessively high oxygen supply only causes higher costs, but does not improve the quality. That is, it can be seen that there is an optimal supply of oxygen.
    Further, it can be seen from Fig. 7 that the vacuum degree VAMIN decreases with the lowest pressure (air pressure) as the oxygen supply amount increases. On the other hand, as explained above, the larger the oxygen supply amount, the smaller the amount of gas. Therefore, it can be seen from Fig. 7 that there is a correlation between the vacuum degree VAMIN with the lowest pressure and the gas amount. Accordingly, this means that the "good / erroneous" judgment of the quality of the die-cast product can be made on the basis of the vacuum degree VAMIN having the lowest pressure.
    The drop in the degree of vacuum VAMIN having the lowest pressure (air pressure) in view of an increase in the oxygen supply amount weakens as the oxygen supply amount exceeds a predetermined amount, the same as the decrease in the gas amount. It should be noted that, in FIG. 7, the oxygen supply amount at which the waste at the vacuum degree VAMIN weakens with the lowest pressure is larger than the oxygen supply amount at which the decrease in the gas amount weakens. Accordingly, the oxygen supply amount at which the waste at the vacuum level VAMIN weakens with the lowest pressure will be the oxygen supply amount obtained by adding a predetermined additional tolerance to the optimum oxidation supply amount.
    It should be noted that in Fig. 7, the amount of gas measured by the gas amount measuring unit as a parameter showing the quality in terms of the voids amount was used. However, instead of the gas amount, the amount of voids itself obtained by CT X-ray analysis or the like of the die-cast product may also be used as a parameter showing the quality with respect to the voids amount, and data obtained in Fig. 7.
    Based on the results obtained in Fig. 7 as described above, the quality management apparatus 3 performs the quality management for the die-cast product as follows.
    In the "good / erroneous" judgment of the quality of the die-cast product with respect to the amount of voids, a product is judged to be defective when the vacuum degree VAMIN having the lowest pressure (air pressure) is higher than a predetermined threshold value VALT, while good product is judged if the former is not higher than the latter.
    The threshold VALT is preferably set for each shape. This is because the data as shown in Fig. 7 differs depending on the shape. It should be noted that the threshold value VALT can be obtained from the data shown in FIG. 7 obtained by experiments or the like for a shape. A database is created from such data, data of the most similar form is extracted from the database, and the threshold value VALT can also be determined from the extracted data. The threshold value VALT can be calculated from a theoretical formula or an equation obtained by regression analysis, as well as using information on the shape of the shape as a parameter.
    The threshold value VALT may be, for example, the value of the mold vacuum degree VA corresponding to the quality level (the amount of voids or gas) with respect to the voids amount required in the die-cast product or a value smaller by a predetermined amount as this. It should be noted that the required quality level differs depending on the type and so on of the die-cast product.
    Further, for example, the threshold value VALT may be the value of the mold vacuum degree VA corresponding to the quality level at the time when the quality improvement (decrease in the amount of voids or gas) with respect to the voids amount decreases with respect to the increase in the oxygen supply amount. In other words, the threshold value VALT may be determined as the value of the mold vacuum degree VA corresponding to the optimum oxygen supply amount.
    Further, the threshold value VALT may be, for example, the value of the mold vacuum degree VA at the time when the mold vacuum degree VA weakens with respect to an increase in the oxygen supply amount. In other words, the threshold value VALT may be the value of the mold vacuum degree VA corresponding to the oxygen supply amount obtained by adding a predetermined additional tolerance to the optimum oxygen supply amount.
    Further, the oxygen supply amount is set for each mold at step S10, so that the mold vacuum degree VA becomes the threshold value VALT or less.
    For example, the oxygen supply amount becomes the oxygen supply amount at the time when the value of the mold vacuum degree VA is the threshold value VA or a value larger than or equal to a predetermined additional tolerance. The additional tolerance can be adjusted empirically appropriately.
    Otherwise, the oxygen supply amount becomes, for example, the oxygen supply amount at the time when the improvement in the quality (decrease in the amount of voids or gas) with respect to the voids amount decreases with an increase in the oxygen supply amount (optimum oxygen supply amount). It should be noted that the threshold value VALT at this time may be a value of the mold vacuum degree VA which corresponds to this oxygen supply amount, but this need not be the case.
    Otherwise, for example, the oxygen supply amount becomes the oxygen supply amount at the time when the mold vacuum degree VA weakens with respect to an increase in the oxygen supply amount (the value obtained by adding an additional tolerance to the optimum oxygen supply amount). At this time, the threshold value VALT may be the value of the mold vacuum degree VA corresponding to this oxygen supply amount, but this need not be the case.
    In the same manner as the threshold value VALT, the oxygen supply amount can be determined from the data shown in Fig. 7 obtained by experiments or the like for a mold. A database is created from such data, data of the most similar form is extracted from the database, and the oxygen supply amount can also be determined from extracted data. The oxygen supply amount may be calculated from a theoretical formula or an equation obtained by regression analysis using information regarding the shape of the mold and the threshold value VALT as a parameter.
    It should be noted that it is also possible to set a general oxygen supply amount with respect to two or more mold types by adjusting the oxygen supply to a sufficiently large amount.
    FIG. 8 is a flowchart showing the quality management routine that the quality management device 3 executes. The processing is repeatedly executed in synchronism with the molding cycle shown in FIG.
    At step S21, the control device 70 waits until the high-speed fill operation is started. When the high-speed filling operation is started, the routine proceeds to step S22.
    At step S22, the controller 70 obtains data on the mold vacuum degree VA based on the detection signal from the vacuum sensor 51. This data extraction continues until it is judged at step S23 that the increase control has started. Further, when it is judged that the increase control has been started, the control device 70 proceeds to step S24.
    At step S24, the control device 70 searches and extracts data indicating the lowest pressure, i. E. the lowest degree of vacuum VAMIN, from the shape-vacuum degree VA time-up data obtained in step S22.
    It should be noted that instead of the search in the timing data in step S24 between step S22 and S23, determining the first obtained mold vacuum degree VA as a temporary vacuum degree VAMIN with the lowest pressure can be inserted, and then when a mold vacuum degree VA with lower pressure than the temporary vacuum degree VAMIN having the lowest pressure is obtained, this mold vacuum degree VA showing a lower pressure becomes a new temporary vacuum degree VAMIN having the lowest pressure.
    At step S25, it is judged whether the vacuum degree VAMIN having the lowest pressure is higher than the threshold value VALT. If it is judged that it is not higher, the product is judged to be a good product (step S26), while if judged to be higher, it is judged to be a defective product (step S27). It should be noted that at step S26 and S27, for example, in the control device 70, a mark "good / erroneous" is set.
    At step S28, processing is performed according to the results of the judgment. In the case of an assessment as a good product, this is reported to the reporting unit 72, for example. The sorter 74 also brings the die cast product to the destination of good product transportation. On the other hand, when a product is judged to be a defective product, it is notified to the notification unit 72, and the sorter 74 brings the die-cast product to the destination of the defective product transport.
    It should be noted that processing for stopping the molding cycle may also be carried out when the number of the defective product judgments and / or a ratio thereof exceeds a predetermined reference value, or the divergence between the lowest pressure VAMIN degree of vacuum and the threshold VALT is large.
    According to the above embodiment, the quality management apparatus 3 performs quality management for a die-cast product formed according to the non-porous die-casting method in which oxygen is supplied into the cavity Ca and the injection sleeve 27 connected to the cavity Ca and, in this state, the melt in FIG the injection sleeve 27 is delivered to the cavity Ca. The quality management device 3 further includes the vacuum sensor 51 that detects the air pressure in the cavity Ca, and the control device 70 that performs the "good / erroneous judgment on the quality of the die-cast product with respect to the voids amount based on the air pressure, of the vacuum sensor 51 is detected during filling or injection.
    Accordingly, the "good / erroneous" judgment of the quality with respect to the voids amount can be made in a short time. It is also possible, for example, to perform the "good / erroneous" assessment of the quality of the die cast product with respect to the voids amount in the molding cycle. Consequently, it becomes possible to inform a worker through the notification unit 72 in the molding cycle that the voids amount is large, to increase the oxygen supply amount, or to interrupt the molding cycle and take other immediate countermeasures. Furthermore, it becomes possible to classify the die-cast products immediately after removal from the mold 101 into products with a large amount of voids and products with a small amount of voids. The configuration is further simple and small, since only one vacuum sensor 51 is provided.
    The control device 70 judges, at a time when the lowest air pressure (the lowest pressure VAMIN degree of vacuum) detected by the vacuum sensor 51 at the time of filling is higher than the predetermined threshold VALT that there is an error. Accordingly, the processing is easy.
    The vacuum sensor 51 is connected to the vent passage 60 for venting the cavity Ca. Accordingly, collision of the filled melt with the vacuum sensor 51 is inhibited, so that it is protected.
    The quality management device 3 further comprises a check valve 52, which allows a flow from the vent passage 60 to the outside at atmospheric pressure, but prevents flow from the outside to the vent passage 60. Accordingly, at the time when the pressure in the cavity Ca is higher than the atmospheric pressure, this pressure is suppressed from being added to the vacuum sensor 51, and the vacuum sensor 51 is protected. When the pressure in the cavity Ca is lower than the atmospheric pressure, the degree of vacuum in the cavity Ca is measured by the vacuum sensor 51.
    The die-casting molding machine 1 comprises: the clamp 5 holding the mold 101 configuring the cavity Ca, the injector 7 being arranged to melt in the injection sleeve 27 connected to the cavity Ca. Cavity Ca, the oxygen supply unit 11, which is adapted to supply the injection sleeve, the active gas (oxygen), the vacuum sensor 51, which is adapted to detect the air pressure in the cavity Ca, and the control device 70, the "good / incorrect" Judgment on the quality of the die-cast product with respect to the voids amount based on the air pressure detected by the vacuum sensor 51 at the time of filling.
    As explained above, it is possible to judge the quality in the molding cycle via the vacuum sensor 51 and the control device 70 (quality management device 3), which makes the "good / erroneous" judgment based on the detection value. By providing such a configuration in the die-casting molding machine 1, a preferable operation of the die-casting molding machine 1 becomes possible.
    [0096] (modification)
    In the first embodiment, the oxygen supply amount supplied in step S10 is set in advance on the basis of, for example, data shown in Fig. 7, and so on. However, as will be explained in the following modification, the oxygen supply amount may be adjusted based on the check of the quality of the die-cast product.
    9 is a flowchart according to the modification showing the routine for adjusting the oxygen supply amount performed in a die-cast forming machine 1 having the same configuration as that in the first embodiment. The processing is repeatedly executed in synchronism with the molding cycle shown in FIG. 5 in the same manner as the processing in FIG.
    It should be noted that this processing can be performed only at a certain time, such as in a trial operation of the die-casting molding machine, or at the start of operation, and also in advance for determining the oxygen supply amount.
    The steps S21 to S25 are similar to the steps S21 to S25 in FIG. 8.
    When it is judged at step S25 that the vacuum degree VAMIN having the lowest pressure detected by the vacuum sensor 51 is greater than the threshold value VALT (defective product judgment), the control device 70 increases the oxygen supply amount setting value (step S32, step S32) S31 will be explained later) while maintaining the oxygen supply amount set value unless judged so. Then the routine goes to the next cycle.
    Then, in the next cycle, at step S11 in Fig. 5, the sleeve 27 is supplied with oxygen according to the value obtained at the processing in Fig. 9, or the increased set value. With an increased oxygen supply value, it can be expected that the vacuum level VAMIN with the lowest pressure will be lower than in the previous cycle. Further, by repeating the molding cycle, the oxygen supply amount setting value will converge.
    It should be noted that the amount of increase in the oxygen supply amount at step S32 may be a fixed amount determined in advance, or may be a value equal to the difference between the vacuum degree VAMIN having the lowest pressure and the threshold value VALT equivalent.
    Here, as explained with reference to FIG. 7, even if the oxygen supply amount is increased and exceeds the predetermined amount, the vacuum degree VAMIN with the lowest pressure does not improve. Accordingly, if judgment is made as a good product at step S25, even though the oxygen supply amount has already exceeded a level at which the decrease of the vacuum degree VAMIN weakens with the lowest pressure, any irregularity is expected or the adjustment of the threshold value VALT is unsuitable was.
    Therefore, at step S31, the control device 70 judges whether the condition of an increase of the supplied oxygen already before the current cycle and which does not exceed a predetermined (appropriately set) predetermined level (an example of a continuation condition) has been satisfied and / or whether the condition of increasing the oxygen supply amount in the current cycle with respect to the previous cycle and decreasing the vacuum degree VAMIN when filling in the current cycle is satisfied compared to the previous cycle (an example of a continuation condition).
    Then, the control device 70 executes step S32 only when a continuation condition is satisfied. If these are not fulfilled, this is reported by the reporting unit 72, or processing is performed to interrupt the cycle.
    It should be noted that step 25 substantially corresponds to the "good / erroneous" judgment of the quality of a die-cast product with respect to the voids amount, so that the die-cast forming machine 1 performing the processing shown in FIG. 9 , adequately checks the quality of the die-cast product with respect to the amount of voids in the same manner as in the first embodiment. Further, even in the modification, steps S <b> 26 to S <b> 28 in FIG. 8 may be executed.
    [Second Embodiment]
    In the first embodiment and modification, the "good / erroneous" judgment, etc. are made on the basis of the vacuum degree VAMIN having the lowest pressure. In contrast, in the second embodiment, the "good / erroneous" judgment is made on the basis of the time when the degree of vacuum is in the mold (mold vacuum time VAT, see FIG. 6). This looks like this.
    The mold vacuum duration VAT is the time for which the air pressure in the mold when filling is below the atmospheric pressure. It should be noted that the mold vacuum duration VAT is usually included in the time when the high-speed filling operation is performed, and shortened when the oxygen supply amount is insufficient, etc.
    Fig. 10 shows the relationship between the mold vacuum duration VAT and the amount of gas contained in the die-cast product.
    From Fig. 10 it can be seen that the gas quantity decreases as the mold vacuum time VAT increases, and a die cast product of higher quality is formed. However, if the mold vacuum duration VAT exceeds a predetermined length, the decrease of the gas amount weakens with respect to an increase in the mold vacuum period VAT.
    Accordingly, in the same manner as in the case of using the lowest pressure VAMIN degree of vacuum, the "good / erroneous" judgment can adequately be made by judging at the time that there is an error when the mold vacuum time VTA is shorter than the setpoint time VAST (corresponding to the threshold value VALT).
    The target time VAST and the oxygen supply amount can be set in the same manner as in the first embodiment. That is, the target time VAST and the oxygen supply amount are preferably set for each shape and can be set based on data, an equation, etc. The target time VAST may further be of a duration corresponding to the quality level required in the die-cast product, or longer, or a length at which the improvement in quality weakens with respect to an increase in the oxygen supply amount, or a length at which the Mold vacuum duration attenuates VAT with respect to an increase in the oxygen supply amount. The oxygen supply amount may further be an amount by which the mold vacuum period VAT equals at least the target time VAST, or an amount by which the improvement in quality with respect to an increase in the oxygen supply amount is weakened, or an amount by which the mold vacuum period VAT in Regarding an increase in the oxygen supply rate attenuates.
    It should be noted that FIG. 11 shows the same test results as FIG. 10, except that here the vacuum degree VAMIN with the lowest pressure is plotted on an abscissa instead of the form vacuum duration VAT. Based on this graph, it can be confirmed that the "good / erroneous" judgment can suitably be made even if the molding vacuum duration VAT or the vacuum degree VAMIN having the lowest pressure is used. It should be noted that in the experimental results, the mold vacuum duration VAT has a stronger correlation with the gas amount than the vacuum degree VAMIN with the lowest pressure.
    The configuration and the general operation of the die-casting molding machine in the second embodiment are similar to the die-casting molding machine 1 in the first embodiment explained with reference to FIGS. 1 to 6. Further, in the die-casting molding machine 1 in the second embodiment, processing similar to that explained with reference to FIG. 8 is also performed.
    In the second embodiment, however, at step S24 in Fig. 8, instead of the vacuum degree VAMIN having the lowest pressure, the mold vacuum duration VAT is extracted. Further, at step S25 in FIG. 8, instead of judging whether the vacuum degree VAMIN having the lowest pressure is greater than the threshold value VALT, judgment is made as to whether the mold vacuum duration VTA is shorter than the target time VAST.
    Further, the product is judged erroneous when it is judged that the mold vacuum duration V T is shorter than the target time VAST (step S27). Otherwise, it is judged to be a good product (step S26).
    Further, the die-casting molding machine 1 in the second embodiment can control the amount of oxygen supply based on the molding vacuum period VAT in the same manner as in the modification shown in FIG. 9. That is, as shown in Fig. 8, where the vacuum degree VAMIN having the lowest pressure at step S24 and S25 has been replaced by the mold vacuum duration VAT, the vacuum degree VAMIN having the lowest pressure at step S24 and S25 in Fig. 9 may be reduced by the mold vacuum duration VAT be replaced.
    The die-casting forming machine is not limited to a horizontal mold-closing and horizontal-filling type, and may be of a vertical-mold-closing or vertical-filling type. The method for supplying melt to the injection sleeve is not limited to one with Giesspfanne and may for example be one with an electromagnetic pump.
    The filling is not limited to a filling operation at low speed and at high speed. The filling may, for example, be carried out at a constant rate until the melt is substantially filled in the cavity, or comprise a plurality of changes in velocity.
    The detection of the pressure by the vacuum sensor can be done not only in a high-speed filling operation or only in filling, but also in other steps. Further, the "good / erroneous" judgment based on the pressure detected by the vacuum sensor may be made based on the pressure detected in a longer step including the filling step. As shown in Fig. 7, the timing at which the drop of the air pressure in the mold occurs is the timing at which the filling takes place at a relatively high speed. The "good / erroneous" judgment based on the pressure detected by the vacuum sensor becomes, in essence, the "good / erroneous" judgment based on the pressure detected by the vacuum sensor at the time of filling.
    The "good / bad" judgment is not limited to the alternative judgment as to whether a product is a good or a defective product, but may also be an assessment of which of the ranked quality levels a product belongs to ,
    The information displayed by the reporting unit may change according to the multiple ranks of the quality levels, or the sorting by the sorting device may be performed according to the multiple ranks of the quality levels.
    The score for the "good / erroneous" judgment is not limited to the vacuum degree VAMIN having the lowest pressure or the mold vacuum duration VAT. The index may be, for example, the average degree of vacuum upon filling or the time at which the pressure in the mold becomes less than a predetermined reference pressure (in the case where the reference pressure is the atmospheric pressure, however, it is the mold vacuum period VAT). Further, for example, an equation for calculating the voids amount from the detected air pressure may be found in advance by regression analysis, the voids amount may be calculated on the basis of the detected pressure, and also used as a measure. That is, a value detected by the vacuum sensor may also be used as a measure obtained by applying a predetermined operation to the air pressure, and so on.
    The cooling channel is not an absolute prerequisite for the venting channel. The vacuum sensor may also be provided in the cavity instead of in the venting channel. The reporting unit and the sorting device are not absolute requirements in the present invention and can also be omitted.
    LIST OF REFERENCE NUMBERS
    [0127]<Tb> 1 <September> die-cast molding machine<Tb> 3 <September> Quality Management Device<Tb> 23 <September> injection sleeve<Tb> 51 <September> vacuum sensor<Tb> 70 <September> control device<Tb> Ca <September> cavity<Tb> 72 <September> Reporting unit<Tb> 52 <September> check valve<Tb> 60 <September> vent channel<Tb> 27 <September> injection sleeve
    权利要求:
    Claims (8)
    [1]
    A quality management apparatus (3) for a die-cast product formed by a non-porous die casting method by which an active gas can be fed into a cavity and an injection sleeve of a die-casting machine connected to the cavity and in this state a melt located in the injection sleeve into which cavity is dischargeable, the device comprising:a vacuum sensor (51) by means of which the air pressure in the cavity can be detected, anda control device (70) by means of which a good / erroneous evaluation of the quality of the die cast product with respect to the voids amount on the basis of the air pressure detectable by the vacuum sensor (51) during filling, wherein the control device (70) judges that a fault exists when a lowest air pressure or a mean degree of vacuum, which is detectable by the vacuum sensor (51) during filling, is higher than a predetermined threshold orwherein the control device judges that there is an error when a time period during which the air pressure detected by the vacuum sensor (51) at filling is less than a predetermined reference pressure which is at most the atmospheric pressure is shorter than a predetermined target time period.
    [2]
    The quality management apparatus of claim 1, further comprising:a reporting unit (72), by means of which the results of the assessment by the control device until the beginning of the next cycle are notified.
    [3]
    The quality management apparatus according to any one of claims 1 to 2, further comprising:a sorting device, by means of which the die-cast products can be sorted according to the results of the assessment by the control device.
    [4]
    4. Die casting molding machine (1) with a quality management device according to one of the preceding claims 1 to 3, comprising:a clamping device (5) which holds a shape, theconfigured a cavityan injection device (7), by means of which a melt in an injection sleeve (27), which is connected to the cavity, is deliverable into the cavity,an Aktivgaszufuhreinheit, by means of which the injection sleeve active gas can be supplied,a vacuum sensor (51) by means of which an air pressure in the cavity can be detected, anda control device (70) by means of which a good / erroneous judgment of the quality of the die cast product with respect to the voids amount on the basis of the air pressure can be made, which is detectable by the vacuum sensor during filling.
    [5]
    5. Die-casting molding machine according to claim 4,wherein the control device (70) is configured to control the active gas supply unit based on the air pressure detectable by the vacuum sensor (51).
    [6]
    6. Die-casting molding machine according to claim 4 or 5, whereinthe control device (70) increases the active gas supplied from the active gas supply unit in the next cycle when a lowest air pressure detectable by the vacuum sensor upon filling is higher than a predetermined threshold value.
    [7]
    A die-casting molding machine according to claim 4, whereinthe vacuum sensor (51) is connected to a vent passage (60) which vents the cavity.
    [8]
    8. Die casting molding machine according to claim 7, further comprising:a check valve (52), which allows under atmospheric pressure, a flow from the vent passage (60) to the outside and prevents flow from the outside to the vent passage.
    类似技术:
    公开号 | 公开日 | 专利标题
    DE112011103901B4|2015-05-07|Quality Management Device and Die Casting Machine
    DE19983014B4|2005-05-25|Diagnostic apparatus for detecting faults in a fuel system
    DE112006002248B4|2014-04-24|Device for automatic brake control
    EP1920300B1|2010-07-28|Method and device for automatically monitoring repetitive operational sequences of an injection molding machine
    EP1306187B1|2007-04-18|Compounding-Injection moulding machine
    DE112011100051T5|2012-10-04|Casting method of an injection molding machine
    DE102004007668A1|2004-09-02|Motor vehicle braking control apparatus, determines if stroke simulator is faulty based on change in output signal from hydraulic pressure sensor before and after opening of on-off valve
    EP2338819B2|2021-02-24|Monitoring the quality of splices in an elongated textile test material
    DE102007061775A1|2009-07-02|Injection molding method, involves comparing mean value, maximum value, point of time, initial gradient and time constants with provided parameter set point, and determining dwell pressure value for subsequent injection molding operation
    MXPA03008519A|2004-07-23|Apparatus and method for manufacturing die-cast product.
    DE3204798C2|1991-04-25|
    EP1893380A1|2008-03-05|Device and method for monitoring a production method for the preparation of a through drilling
    EP0880732B1|2000-02-16|Method and device for examining and/or adjusting valves
    DE112012001905T5|2014-02-06|Detecting a change in the orientation of the central axis of a mold carrier plate device
    DE4313800B4|2005-05-04|Vacuum die casting process
    DE60129875T2|2008-05-15|Cast product ejection check device
    DE102014014525A1|2015-04-09|Injection molding system that can detect pressure abnormalities
    DE19801881C1|1999-05-27|Assessment of molding quality achieved by pressure injection molding machine
    DE3204799A1|1982-09-09|DEVICE FOR ELECTRICAL DISCHARGE PROCESSING OF WORKPIECES
    DE19952708B4|2008-06-12|Injection control method and device of a die-casting machine
    DE102005002448A1|2006-07-27|Apparatus and method for measuring, controlling or testing
    EP0233548B1|1992-07-15|Method and apparatus for regulating the injection moulding process
    DE10218499B4|2005-05-19|Method for monitoring the mold opening force in an electric injection molding machine
    DE10140657C1|2002-11-07|Device for measuring the pressures in a mold filled with a melt used in vacuum die casting machines comprises measuring channels arranged in direct contact with the hollow space of the mold
    DE102012100928A1|2012-08-16|A motor drive control device that adjusts the output of an engine depending on the supply performance of an AC power supply
    同族专利:
    公开号 | 公开日
    WO2012070426A1|2012-05-31|
    DE112011103901B4|2015-05-07|
    JP5770012B2|2015-08-26|
    US20130255902A1|2013-10-03|
    DE112011103901T5|2013-12-24|
    US9132477B2|2015-09-15|
    JP2012125839A|2012-07-05|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    NL135443C|1966-06-30|
    JP2876949B2|1993-08-31|1999-03-31|日産自動車株式会社|Cavity humidity measurement method in vacuum die casting and quality control method in vacuum die casting|
    DE19628870A1|1996-07-17|1998-01-22|Alusuisse Bayrisches Druckgus|Device and method for producing die-cast parts|
    JP3508627B2|1998-07-14|2004-03-22|日本軽金属株式会社|Die casting method and die casting products|
    EP1034863A1|1999-03-05|2000-09-13|Alusuisse Technology &amp; Management AG|Method for die casting of light metals|
    MY130713A|2000-01-12|2007-07-31|Nippon Light Metal Co|A die-casting process and a die-casting machine|
    JP3961929B2|2002-11-06|2007-08-22|東芝機械株式会社|Die casting machine|
    US6953079B2|2002-11-06|2005-10-11|Toshiba Kikai Kabushiki Kaisha|Die casting machine|
    JP4510481B2|2004-02-17|2010-07-21|キヤノン株式会社|Information processing apparatus and information processing method|
    JP2006183122A|2004-12-28|2006-07-13|Denso Corp|Aluminum alloy for die casting and method for producing aluminum alloy casting|
    JP2006315022A|2005-05-11|2006-11-24|Toyota Motor Corp|Apparatus and method for measuring ambient atmosphere inside die|
    JP5179212B2|2008-02-04|2013-04-10|東芝機械株式会社|Molding support apparatus and molding condition determination method|EP2821772A4|2012-02-29|2015-10-21|Nsk Ltd|Die-cast product rigidity evaluation method and die-cast product|
    CN103586437B|2013-11-26|2016-04-06|美诺精密压铸有限公司|Die casting and comprise its die-casting system|
    JP6745642B2|2016-05-10|2020-08-26|芝浦機械株式会社|Die casting machine and method for forming solid-liquid coexisting metal|
    CN107498010B|2017-08-22|2019-03-12|珠海市润星泰电器有限公司|A kind of preparation process of light alloy semisolid slurry|
    CN107745106A|2017-09-22|2018-03-02|芜湖市鸿坤汽车零部件有限公司|A kind of automobile metal accessory Casting Equipment|
    CA3090701A1|2018-02-13|2019-08-22|F&S Tool, Inc.|Light weight mold support structure in a single dual injection molding machine|
    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    JP2010260907|2010-11-24|
    JP2011108424A|JP5770012B2|2010-11-24|2011-05-13|Quality control device and die casting machine|
    PCT/JP2011/076275|WO2012070426A1|2010-11-24|2011-11-15|Quality management device and die casting machine|
    [返回顶部]