Sand mould identification device

The sand mould identification device has a housing with an identification pattern face adapted to be arranged in a pattern forming surface of a sand moulding machine. Individually adjustable indicator elements in the identification pattern face are adjustable by means of an actuator. The housing includes an insertion portion adapted to be inserted into a corresponding recess of said sand moulding machine. The identification pattern face is located at a front end of the insertion portion. The insertion portion is adapted to be inserted into the sand moulding machine in an insertion direction extending from a rear end to the front end of the insertion portion. A mounting bracket is accessible at or behind the rear end of the insertion portion for mounting or demounting the housing to or from the sand moulding machine or core shooter.

BACKGROUND OF THE INVENTION

The present invention relates to a sand mould identification device with a housing including an identification pattern face adapted to be arranged in a pattern forming surface of a sand moulding machine or a core shooter, wherein a plurality of individually adjustable indicator elements are arranged rotationally in the identification pattern face, the rotational position of each individual indicator element being adjustable by means of an actuator, wherein the housing includes an insertion portion adapted to be inserted into a corresponding recess of said sand moulding machine or core shooter and having a front end and a rear end, wherein the identification pattern face is located at the front end of the insertion portion, wherein at least a part of each actuator is inserted into the insertion portion, and wherein the housing includes a mounting device for mounting the housing to the sand moulding machine or core shooter.

WO 2017/025266 A1 discloses a sand mould identification device comprising a housing, which has a mould forming surface, in which a plurality of individually adjustable indicator elements are arranged, each of which being surrounded by a frame element, wherein each indicator is connected with a respective actuator arranged in the housing, the actuators being operatively connected to an electronic control for individual adjustment of the indicator elements. Each individually adjustable indicator element has a symmetrical needle form and may be positioned in four different recognisable positions. The illustrated embodiment has six indicator elements resulting in 4,096 different possible combinations. The mould forming surface is arranged on a cover plate protruding around the housing and thereby forming a mounting flange adapted to abut a pattern of a pattern plate in a sand moulding machine. The mounting flange is provided with holes for mounting screws. However, it is a disadvantage that this device is rather bulky and has a large footprint in the sand mould pattern. As a consequence, the device is not suitable for smaller castings or castings having many details on the surface. Furthermore, in a modern foundry production line producing up to about 5000 castings per hour, in order to obtain suitable traceability of the produced castings for retrieval of related production and quality data, many more different combinations of the indicator elements are required than what is possible with this device.

U.S. Pat. No. 4,137,962 discloses a casting-marking apparatus adapted for incorporation in a permanent foundry pattern of the type used to produce sand moulds for metal casting. The apparatus carries a marking that is impressed in the sand mould and subsequently reproduced on a casting. The apparatus is designed and constructed so that the marking that it carries can be altered from a station remote from the pattern. In the apparatus, the alterable marking is carried out by a marking body that is rotated by an air actuated piston. However, this apparatus is adjustable for only 12 different identification marks to be produced by the marking body. As explained above, in a modern foundry production line, many more different combinations are required than what is possible with this device. Although more different combinations could be achieved by providing more marking bodies, the illustrated embodiment having one marking body is already too bulky for most commonly occurring castings. U.S. Pat. No. 7,252,136 B2 discloses a similar device.

US 2002/0059874 A1 discloses an automated date insert that imprints the date on a moulded product. The automatic date insert includes a front face with attached indicators that mark a date pattern onto the surface of the moulded product. Each indicator is operatively connected to an indicating means that imprints a date on the moulded product that corresponds to the date pattern of the indicator. The indicating means is operatively connected to an electric motor that is activated and controlled by a processing means such that the electric motor causes the indicator means to move a pre-selected amount corresponding to a pre-determined time or date interval transmitted by the processing means. However, this device is rather bulky even though the number of different combinations that may be achieved are not enough for a modern foundry production line.

In a modern foundry production line, foundry quality costs may indeed be very high. For instance, in the production of demanding automotive products, the combined quality costs related to the rejection of defective castings at foundry and user of the castings may be up to 10 percent of the total production costs. When castings are rejected due to quality issues, many consequential costs may be incurred. The possible causes for rejection must be analysed and production may have to be adapted accordingly, whereby production may be delayed. However, with prior art casting-marking solutions, it has not been possible to link bad quality for individual castings with relevant process parameters. Rather, it has only been possible to link batch-based quality data like percentage of castings defective due to sand inclusions, percentage of castings defective due to porosities, etc. with batch-based process parameters. As a consequence, it has proven very difficult to further reduce quality costs.

SUMMARY OF THE INVENTION

The object of the present invention is to provide a compact sand mould identification device suitable for providing a large number of different combinations of the indicator elements.

In view of this object, in the assembled state of the sand mould identification device, the insertion portion is adapted to be inserted into the sand moulding machine or core shooter in an insertion direction extending from the rear end to the front end of the insertion portion, the mounting device is accessible at or behind the rear end of the insertion portion for mounting or demounting the housing to or from the sand moulding machine or core shooter, and the mounting device has the form of a mounting bracket arranged at or behind the rear end of the insertion portion and protruding in relation to the insertion portion in a direction being transverse to the insertion direction.

In this way, by adapting the insertion portion to be inserted into the sand moulding machine or core shooter from a rear side of the pattern forming surface, and by arranging the mounting device in the form of the mounting bracket to be accessible at or behind the rear end of the insertion portion, a very little footprint of the sand mould identification device in the pattern forming surface may be achieved while at the same time a suitable number of individually adjustable indicator elements may be arranged rotationally in the identification pattern face. Thereby, a large number of different combinations of the indicator elements may be achieved.

In an embodiment, a motor control for the actuators and a network adaptor is arranged behind the rear end of the insertion portion. Thereby, a motor control and a network adaptor may be arranged in the housing while the insertion portion may still have a compact configuration.

In a structurally particularly advantageous embodiment, the insertion portion forms part of a mounting block forming protrusions extending in opposed directions at the rear end of the insertion portion, and the mounting bracket is fastened to the respective protrusions preferably by means of bolts.

In a structurally particularly advantageous embodiment, the actuators are arranged along a central line of the mounting block extending between the protrusions of the mounting block, the mounting bracket forms opposed mounting flanges at either side of the central line of the mounting block, and the mounting flanges are adapted to be mounted on the sand moulding machine or core shooter preferably by means of bolts. Thereby, a slim insertion portion may be achieved resulting in that the sand mould identification device may have a small footprint in the pattern forming surface.

In an embodiment, the mounting bracket includes a first bracket part and a second bracket part clamped together and gripping on either side of a part of each actuator. Thereby, by using the mounting bracket as a fixture for the actuators, an even more compact device may be achieved.

In an embodiment, an elastic element is sandwiched between the actuators and the first and second bracket parts. Thereby, the actuators may be even better secured in the housing.

In a structurally particularly advantageous embodiment, a printed circuit board including the motor control and the network adaptor abuts the first and second bracket parts oppositely the insertion portion. Thereby, an even more compact device may be achieved.

In a structurally particularly advantageous embodiment, a rear end of an electric motor of each actuator extends through a hole in the printed circuit board. Thereby, an even more compact device may be achieved. The total dimensions of the housing may be very small in relation to the dimensions of the actuators.

In an embodiment, the printed circuit board is partly covered by a cover so that an edge of the printed circuit board extends from the cover and is provided with at least one network connector part. Thereby, the printed circuit board may be covered and at the same time, a compact device may be achieved.

In a structurally particularly advantageous embodiment, each individually adjustable indicator element is arranged at a front end of a cylindrical part fitting in a corresponding bore of the insertion portion, a rear end of the cylindrical part engages a shaft end of the corresponding actuator, and the cylindrical part and/or the corresponding bore has a recess in which a sealing ring is arranged. The sealing ring may prevent sand and dust from reaching the internal of the housing.

In an embodiment, a first end stop protrusion is arranged on the cylindrical part, and a second corresponding end stop protrusion is arranged in the corresponding bore of the insertion portion. Thereby, the motor control may reset the starting position of the actuators when the first and second end stop protrusions abut each other, and consequently a more accurate control of the individually adjustable indicator elements may be achieved.

In an embodiment, the sealing ring is arranged between the front end of the cylindrical part and the first end stop protrusion arranged on the cylindrical part.

Thereby, the sealing ring may prevent sand and dust from reaching the first and second end stop protrusions and thereby negatively influencing the resetting of the starting position of the actuators.

In an embodiment, the rear end of the cylindrical part is provided with a partly cylindrical hole having an axially extending flat face corresponding to an axially extending flat face of the shaft end of the corresponding actuator, and said shaft end engages the partly cylindrical hole. Thereby, a very precise connection between the rear end of the cylindrical part and the shaft end of the actuator is possible even for very small dimension of the cylindrical part and the shaft end, such as a general diameter in the order of for instance 0.75 mm, 1.5 mm or 2 mm.

In an embodiment, the network adaptor of the sand mould identification device is adapted to be connected to a controller of a sand moulding machine by means of a connector including a first connector part adapted to be arranged on a pattern plate of the sand moulding machine and a second connector part adapted to be arranged on the sand moulding machine, each connector part includes a number of electrical contact elements, and the electrical contact elements of the second connector part are adapted to flexibly engage and slide on a top side of the respective electrical contact elements of the first connector part during a mounting operation of the pattern plate on the sand moulding machine. Thereby, a stable, cabled connection to the controller may be provided without risk that sand and dust build up on the contact surfaces of the contact elements of the first and second connector part. Because the electrical contact elements of the second connector part are adapted to flexibly engage and slide on a top side of the respective electrical contact elements of the first connector part during a mounting operation, any sand or dust left on the contact surfaces will be removed by the sliding action at each mounting operation.

In an embodiment, the insertion portion has a cross-sectional dimension transversely to the insertion direction being maximum 30 percent, preferably maximum 20 percent, and most preferred maximum 10 percent larger than a diameter of the part of the actuator inserted into the insertion portion. Thereby, an even more compact device may be achieved.

The present invention further relates to a sand moulding machine including at least one sand mould identification device as described above.

DETAILED DESCRIPTION OF THE INVENTION

FIG.1shows a sand mould identification device1with a housing2including an identification pattern face3adapted to be arranged in a pattern forming surface4of a sand moulding machine5as illustrated inFIGS.10to15. Alternatively, the identification pattern face3may be arranged in a pattern forming surface of a not shown core shooter. The identification pattern face3is adapted to impress or imprint an individual identification pattern in a sand mould or a core for a sand mould. Said individual identification pattern may subsequently be reproduced in a metal casting. Three individually adjustable indicator elements6,7,8are arranged rotationally in the identification pattern face3, and the rotational position of each individual indicator element6,7,8is adjustable by means of an actuator9,10,11as seen for instance inFIGS.5,6and7. The housing2includes an insertion portion12adapted to be inserted into a corresponding recess13of the sand moulding machine5as seen inFIG.10or of a not shown core shooter. The insertion portion12has a front end14and a rear end15, wherein the identification pattern face3is located at the front end14of the insertion portion12. A part of each actuator9,10,11is inserted into the insertion portion12, and the housing2includes a mounting device in the form of a mounting bracket16for mounting the housing2to the sand moulding machine5or core shooter.

In the assembled state of the sand mould identification device1as seen inFIG.1, the insertion portion12is adapted to be inserted into the sand moulding machine or core shooter in an insertion direction D extending from the rear end15to the front end14of the insertion portion12. In other words, the assembled sand mould identification device1is adapted to be mounted in the sand moulding machine5or core shooter by inserting the insertion portion12into the corresponding recess13of the sand moulding machine5or core shooter by displacement of the sand mould identification device1in the direction of the arrow indicating the insertion direction D inFIG.1. As it will be understood, thereby the insertion portion12is inserted into the sand moulding machine5or core shooter from a rear side of the pattern forming surface4. In the illustrated embodiment, the mounting device in the form of the mounting bracket16is arranged at or behind the rear end15of the insertion portion12and protrudes in relation to the insertion portion12in a direction being transverse to the insertion direction D. Alternatively, according to the present invention, the mounting device may simply be accessible at or behind the rear end15of the insertion portion12for mounting or demounting the housing2to or from the sand moulding machine5or core shooter. For instance, the mounting device may have the form of one or more wedges arranged in walls of the insertion portion12so that the wedges may be displaced to press against walls of the corresponding recess13of the sand moulding machine5or core shooter when the insertion portion12is inserted into said recess13. For instance, such wedges may be caused to slide along the insertion direction D in corresponding grooves of walls of the insertion portion12by rotation of screws having screw heads accessible from the rear end15of the insertion portion12. The groove of the wall of the insertion portion12may extend in the insertion direction D and have a bottom which is inclined in relation to the insertion direction, thereby causing the wedge to move in a direction out of the groove when the wedge is displaced along the groove. However, the skilled person will understand that many other embodiments of mounting devices may be adapted be accessible at or behind the rear end15of the insertion portion12for mounting or demounting the housing2to or from the sand moulding machine5or core shooter. For instance, at snap lock type mounting device may be arranged to lock the insertion portion12in the recess13of the sand moulding machine5or core shooter when the insertion portion12is inserted into said recess13. In order to demount the insertion portion12from the recess13, a button of the snap lock type mounting device arranged at or behind the rear end15of the insertion portion12may be adapted to be pressed. In this way, the mounting device does not take up any space at the front end14of the insertion portion12where the identification pattern face3is located.

Thereby, a very little footprint of the sand mould identification device1in the pattern forming surface4may be achieved while at the same time a suitable number of individually adjustable indicator elements6,7,8may be arranged rotationally in the identification pattern face3. Thereby, a large number of different combinations of the indicator elements may be achieved.

ComparingFIGS.1and2, it is seen that the insertion portion12has a cross-sectional dimension CS transversely to the insertion direction D. The cross-sectional dimension CS is maximum 30 percent, preferably maximum 20 percent, and most preferred maximum 10 percent larger than a diameter d of the part of the actuator9,10,11inserted into the insertion portion12. The diameter d of the actuator9,10,11is indicated inFIG.7.

As further seen in the figures, the insertion portion12forms part of a mounting block17forming protrusions18,19extending in opposed directions at and behind the rear end15of the insertion portion12, and the mounting bracket16is fastened to the respective protrusions18,19by means of bolts20.

The three actuators9,10,11are arranged along a central line21of the mounting block17, indicated inFIG.2, extending between the opposed protrusions18,19of the mounting block17. The mounting bracket16forms opposed mounting flanges22,23at either side of the central line21of the mounting block17, and the mounting flanges22,23are adapted to be mounted on the sand moulding machine or core shooter by means of bolts24. Thereby, a slim insertion portion12may be achieved resulting in that the sand mould identification device1may have a small footprint in the pattern forming surface4. As it will be understood, thereby the mounting flanges22,23are adapted to be mounted on the rear side of the pattern forming surface4. The mounting bracket16further includes a first bracket part25and a second bracket part26clamped together and gripping on either side of a part of each actuator9,10,11. By using the mounting bracket16as a fixture for the actuators, an even more compact device may be achieved.

An elastic element27, for instance made of rubber or the like, is sandwiched between the actuators9,10,11and the first and second bracket parts25,26in order to better secure the actuators in the housing. As seen inFIG.7, the elastic element27has a form composed by three connected tubular parts, of which either outer part is open at the corresponding end of the elastic element27. When clamped together by means of clamping bolts62, the first and second bracket parts25,26form an opening corresponding to the outer form of the elastic element27.

A motor control for the actuators9,10,11and a network adaptor is arranged behind the rear end15of the insertion portion12in that a printed circuit board28including the motor control and the network adaptor abuts the first and second bracket parts25,26oppositely the insertion portion12as seen inFIG.4. Thereby, the motor control and a network adaptor may be arranged in the housing2while the insertion portion12may still have a compact configuration. As also illustrated inFIG.4, a rear end29of an electric motor30of each actuator9,10,11extends through a corresponding hole31,32,33in the printed circuit board28, whereby an even more compact device may be achieved. The total dimensions of the housing2may be very small in relation to the dimensions of the actuators9,10,11. In the assembled state of the sand mould identification device1, as illustrated inFIG.3, the printed circuit board28is partly covered by a cover34so that an edge35of the printed circuit board28extends from the cover34and is provided with at least one network connector part36. Thereby, the printed circuit board28may be covered and at the same time, a compact device may be achieved.

As seen inFIG.6, each individually adjustable indicator element6,7,8is arranged at a front end37of a cylindrical part38,39,40fitting in a corresponding bore41,42,43of the insertion portion12, wherein a rear end44of the cylindrical part38,39,40engages a shaft end45of the corresponding actuator9,10,11. As seen, when assembling the sand mould identification device1, the cylindrical parts38,39,40are inserted from the front end14of the insertion portion12and the actuators9,10,11are inserted from the rear end15of the insertion portion12. The cylindrical part38,39,40is provided with a recess46in which a sealing ring47is arranged. The sealing ring47may prevent sand and dust from reaching the internal of the housing2. Alternatively, the corresponding bore41,42,43may be provided with the recess46for the sealing ring47. The sealing ring47may be a type of piston or rod seal and may for instance be of polyurethane (PUR).

Although in the illustrated embodiment, the three rotationally arranged cylindrical parts38,39,40are arranged side by side along the line21corresponding to the arrangement of the actuators9,10,11, as described above, many other arrangements of the rotationally arranged cylindrical parts38,39,40are possible. Furthermore, any other suitable number of rotationally arranged cylindrical parts38,39,40may be arranged in the sand mould identification device1. For instance, three rotationally arranged cylindrical parts38,39,40may be arranged in a triangular arrangement, four rotationally arranged cylindrical parts38,39,40may be arranged in a rectangular or square arrangement or five rotationally arranged cylindrical parts38,39,40may be arranged in a pentagonal or circular configuration. Likewise, a number of sand mould identification devices1may be combined in one pattern forming surface4of a pattern plate56,79in order to obtain a suitable number of rotationally arranged cylindrical parts38,39,40for one pattern forming surface4.

Each individual indicator element6,7,8is formed at the front end37of the respective cylindrical part38,39,40arranged rotationally in the housing2of the sand mould identification device1. Each individual indicator element6,7,8extends in a diametrical direction of the respective cylindrical part38,39,40.

As seen inFIG.9, each individually adjustable indicator element6,7,8is formed with rounded edges and is formed to indicate a direction along a diameter of the corresponding cylindrical part38,39,40on which it is arranged. Preferably, the individually adjustable indicator element is formed with all its edges being rounded so that no sharp edges are present. Sharp edges may be difficult to mould and may be damaged during a shot blasting process. Furthermore, it is seen that each individually adjustable indicator element6,7,8is formed to indicate a direction along the diameter of the corresponding cylindrical part in that the individually adjustable indicator element forms a relatively broad, partly circular part91at a first end of the diameter of the cylindrical part and a relatively narrow, elongated part92at a second end of the diameter of the cylindrical part. The illustrated form of the individually adjustable indicator element may further be said to be more or less drop-like. In other embodiments, the individually adjustable indicator element may be formed to indicate the direction along the diameter of the corresponding cylindrical element in other ways, for instance, the individually adjustable indicator element may taper regularly or irregularly from the first end of said diameter to the second end of said diameter. In other embodiments, the individually adjustable indicator element may have the form of a watch hand, preferably including a kind of arrow-like element.

In an embodiment, each individual indicator element6,7,8illustrated inFIG.9extends at least 0.5 millimetres, preferably at least 0.7 millimetres, and most preferred at least 0.9 millimetres from the corresponding front end37of the cylindrical part38,39,40.

It is preferred that each individually adjustable indicator element6,7,8is formed as a protrusion from the front end of the respective cylindrical part38,39,40arranged rotationally in the housing2of the sand mould identification device1, as seen in the embodiment illustrated in the figures. However, in an alternative embodiment, each or some of the individually adjustable indicator elements6,7,8may be formed as a depression in the front end of the respective cylindrical part38,39,40. It is also possible that a first part of an individually adjustable indicator element6,7,8is formed as a protrusion and a second part of said individually adjustable indicator element is formed as a depression. For instance, the relatively broad, partly circular part91at the first end of the diameter of the cylindrical part38,39,40may be formed as a depression and the relatively narrow, elongated part92at the second end of the diameter of the cylindrical part38,39,40may be formed as a protrusion.

The illustrated embodiment of the individually adjustable indicator element6,7,8is in particular advantageous in a foundry production line including an automatic image detection system adapted to detect the resulting individual identification patterns in the castings. The automatic image detection system may include an imaging device being adapted to provide a 2D digital image of the individual identification pattern, but an imaging device producing a 3D digital image may also be used. The automatic image detection system may include a computer system adapted to run a computer program developed by means of machine learning to analyse the 2D or 3D digital image and thereby detect the individual identification patterns of the castings. With the illustrated embodiment of the individually adjustable indicator element6,7,8, it may even be possible to detect the individual identification pattern of the castings after a finishing treatment in a finishing apparatus adapted to clean castings, such as by means of blasting, such as shot blasting. Such a foundry production line may also advantageously include a computer controlled database system adapted to store data relating to a number of production variables measured and/or set during production and data relating to the quality of the produced castings.

In the embodiment illustrated in the figures, the identification pattern face3of the housing2of the sand mould identification device1includes six stationary alignment elements63adapted to impress an alignment pattern in a sand mould part during its compaction. An automatic image detection system may be adapted to, before detection of an individual identification pattern in a casting, align a 2D or 3D digital image with a reference image of the alignment pattern. Thereby, image detection may be improved in many situations in which it is not possible or not convenient to arrange a casting for image capturing so that the individual identification pattern formed in the casting extends generally at a plane being perpendicular in relation to a camera axis of an imaging device when capturing the 2D or 3D digital image. This may be the case both if the imaging device is arranged in a handheld device or if the imaging device is arranged in a stationary device. As further seen, the three rotationally arranged cylindrical parts38,39,40are arranged side by side along the line21, and the six stationary alignment elements63are arranged asymmetrically about said line in that four of the stationary alignment elements63are arranged along a line below the three rotationally arranged cylindrical parts38,39,40and two of the stationary alignment elements63are arranged along a line above the three rotationally arranged cylindrical parts38,39,40. Of course, many other asymmetrical arrangements of a suitable number of stationary alignment elements63are possible. The asymmetrical arrangement of the stationary alignment elements63may indicate a reading orientation for the impressions provided by the individually adjustable indicator elements6,7,8and the possible number of different combinations that may be achieved by the individually adjustable indicator elements may thereby be increased.

ComparingFIGS.4and6, it is seen that a first end stop protrusion48is arranged on the cylindrical part38,39,40, and a second corresponding end stop protrusion49is arranged in the corresponding bore41,42,43of the insertion portion12. Thereby, the motor control may reset the starting position of the actuators9,10,11when the first and second end stop protrusions48,49abut each other, and consequently a more accurate control of the individually adjustable indicator elements6,7,8may be achieved. The sealing ring47is arranged between the front end37of the cylindrical part38,39,40and the first end stop protrusion48arranged on the cylindrical part. Thereby, the sealing ring47may also prevent sand and dust from reaching the first and second end stop protrusions48,49and thereby negatively influencing the resetting of the starting position of the actuators9,10,11.

As indicated inFIG.4, the rear end44of the cylindrical part38,39,40is provided with a partly cylindrical hole50having an axially extending flat face51corresponding to an axially extending flat face52of the shaft end45of the corresponding actuator9,10,11as illustrated inFIG.6, and the shaft end45engages the partly cylindrical hole50. Thereby, a very precise connection between the rear end44of the cylindrical part38,39,40and the shaft end45of the actuator is possible even for very small dimension of the cylindrical part and the shaft end. As seen inFIG.6, the shaft end45of the corresponding actuator9,10,11is fixed in the partly cylindrical hole50of the rear end44of the corresponding cylindrical part38,39,40by means of a set screw64which is mounted in a corresponding threaded bore65of the rear end44of the corresponding cylindrical part38,39,40so that an end of the set screw64abuts the axially extending flat face52of the shaft end45. The corresponding flat faces51,52of the partly cylindrical hole50and the shaft end45, respectively, may ensure that the shaft end45is correctly orientated in the partly cylindrical hole50so that the set screw64may abut the axially extending flat face52of the shaft end45. Otherwise, if the partly cylindrical hole50were in fact cylindrical, it could be difficult to position the shaft end45correctly in the hole due to the small diameter of the shaft end45. If the set screw64would therefore not correctly engage the flat face52of the shaft end45, the connection between the shaft end and the cylindrical part38,39,40could be unstable.

As also seen inFIG.6, a side wall of the insertion portion12of the housing2is provided with a through hole66for each set screw64so that the connection between each shaft end45and the corresponding cylindrical part38,39,40may be secured when the cylindrical part38,39,40has been inserted into the front end14of the insertion portion12and when a part of the actuator9,10,11has been inserted into the rear end15of the insertion portion12so that the shaft end45is inserted into the cylindrical part38,39,40.

As illustrated inFIGS.11to18, the network adaptor of the sand mould identification device1is adapted to be connected to a not shown controller of a sand moulding machine5by means of a connector53including a first connector part54adapted to be arranged on a pattern plate56of the sand moulding machine and a second connector part55adapted to be arranged on the sand moulding machine5. Each connector part54,55includes a number of electrical contact elements57,58, and the electrical contact elements58of the second connector part55are adapted to flexibly engage and slide on a top side59of the respective electrical contact elements57of the first connector part54during a mounting operation whereby the pattern plate56is mounted on the sand moulding machine5. During the mounting operation, as illustrated inFIG.16, the pattern plate56is brought into engagement with the heating plate77and is mounted thereon by means of bolts, whereby the electrical contact elements58of the second connector55engage the respective electrical contact elements57of the first connector part54and slide on a top side59thereof. Thereby, any sand or dust present on the electrical contact elements57,58will be wiped away and good electrical contact may be established between the electrical contact elements. In this way, a stable network connection may be established between each of the sand mould identification devices1and the not shown controller.

In the illustrated embodiment inFIGS.11to17, the pattern plate56of the sand moulding machine5is provided with two sand mould identification devices1connected to the not shown controller of the sand moulding machine by means of a single connector53including a first connector part54arranged on the pattern plate56and a second connector part55arranged on the sand moulding machine5. As seen, depending on the number of castings to be produced in the sand mould, a corresponding number of sand mould identification devices1are connected one after the other in a line by means of a network cable89which is finally connected to the first connector part54. Each sand mould identification device1includes a printed circuit board28as seen inFIG.1. The second connector part55is connected to the not shown controller arranged in the sand moulding machine5. Thereby, the printed circuit board28of each sand mould identification device1may communicate with the not shown common controller and be provided with power via the network cable89and the connector53. Of course, alternatively to a network cable, the printed circuit board28of each sand mould identification device1may communicate with the not shown controller arranged in the sand moulding machine5by means of wireless radio communication. In this case, each sand mould identification device1may be provided with its own power supply in the form of a battery or the sand mould identification devices1may be supplied with power via cable.

As illustrated inFIG.10, the sand moulding machine5includes a moulding chamber80in which a first pattern plate56arranged on a pressing plate78and a second pattern plate79arranged on a swing plate81are adapted to form respective patterns in either side of a sand mould part during compaction of the sand mould part in the moulding chamber80. As seen, each of the first pattern plate56and the second pattern plate79is provided with a pattern forming surface4. The illustrated sand moulding machine5is a vertical flaskless sand moulding machine of the DISAMATIC (registered trade mark) type. The working principle of this type of sand moulding machine is well-known. The moulding chamber80is filled with sand through a sand filling opening84in a top wall86of the moulding chamber80, and the sand is compacted by displacement of the first and second pattern plates56,79in a direction against each other. Subsequently, the swing plate81is displaced and pivoted to an open position in which the sand mould part may leave the moulding chamber in a direction which is directed to the right inFIG.10. The sand mould part is pressed out of the moulding chamber by displacement of the pressing plate78until the sand mould part abuts the previously produced sand mould part on a not shown sand mould conveyor and a sand mould is formed between those two sand mould parts. Thereby, a string of sand moulds is produced.

The first pattern plate56of the sand moulding machine5illustrated inFIG.10is provided with a single sand mould identification device1according to the present invention.

The controller is adapted to provide each sand mould formed by two sand mould parts with at least one individual identification pattern arranged to form an individual identification pattern in each resulting casting when the sand mould has been filled with molten metal in a melt pouring device. As understood, each sand mould produced by the sand moulding machine5illustrated inFIG.10results in one casting provided with a corresponding identification pattern. However, the pattern plate56illustrated inFIGS.11to17is adapted to form two castings, and therefore, the pattern plate56is provided with two sand mould identification devices1arranged at the respective patterns of the pattern plate56so that each casting may be provided with its own identification pattern. In other embodiments, a pattern plate may be adapted to form three or more castings, and the pattern plate may then be provided with a corresponding number of sand mould identification devices1arranged at the respective patterns.

Although the illustrated sand moulding machine5is a vertical flaskless sand moulding machine, the sand mould identification device1according to the present invention is equally applicable to other types of sand moulding machines, such as a sand moulding machine of the match plate type. In a sand moulding machine of the match plate type, the sand moulding machine includes two moulding chambers separated by means of a match plate. On either side of the match plate, a pattern plate is formed and is adapted to form a corresponding pattern in the corresponding sand mould part during compaction of the sand mould part in the respective moulding chamber. In a sand moulding machine of the match plate type, at least one of the pattern plates formed on the match plate is provided with at least one sand mould identification device1according to the present invention. Thereby, each sand mould formed by two sand mould parts may be provided with at least one individual identification pattern, according to the number of castings to be formed in the sand mould.

As a further example, the sand mould identification device1according to the present invention is equally applicable to a horizontal flask line in which cope and drag are combined to form a flask. Each of the cope and drag is provided with a pattern plate. In a sand moulding machine in a horizontal flask line, at least one of the two pattern plates may be provided with at least one sand mould identification device1according to the present invention. Thereby, each sand mould formed in a flask composed by cope and drag may be provided with at least one individual identification pattern, according to the number of castings formed in the sand mould.

The motor control arranged on the printed circuit board28is adapted to control the actuator9,10,11corresponding to each individual indicator element6,7,8so that the individual indicator element may be positioned in at least 15, preferably at least 20, more preferred at least 30, and most preferred at least 35 different rotational positions about the axis of rotation of the cylindrical part38,39,40. Advantageously, the motor control may be adapted to control the actuator corresponding to each individual indicator element6,7,8so that the individual indicator element may be positioned in about 40 different rotational positions. The motor control may be adapted to control the actuator corresponding to each individual indicator element6,7,8so that the rotational position of the individual indicator element about the axis of rotation of the corresponding cylindrical part is adjusted in increments of less than 20 degrees, preferably of less than 15 degrees, and most preferred of less than 10 degrees.

Purely as an example, the first end stop protrusion48of the cylindrical part38,39,40and the second end stop protrusion49of the bore41,42,43may together take up about 30 degrees of the total possible rotation of the cylindrical part38,39,40in the corresponding bore41,42,43of the insertion portion12. In this case, the actual possible rotation of the cylindrical part from a first rotational end position to a second rotational end position will be about 330 degrees. In the illustrated embodiment, at the first rotational end position, a first side of the first end stop protrusion48of the cylindrical part38,39,40abuts the second end stop protrusion49of the bore41,42,43on a first side thereof, and at the second rotational end position, a second side of the first end stop protrusion48of the cylindrical part38,39,40abuts the second end stop protrusion49of the bore41,42,43on a second side thereof. Thereby both end positions can be detected, and bigger precision can be achieved, furthermore self-diagnostics can be performed.

The electric motor30of each actuator9,10,11is preferably a stepper motor, preferably driven by microstepping the stepper motor. The transmission provided for the electric motor30is preferably a planetary gear60, but other types of transmission are possible, including no gear. As illustrated inFIG.6, a shaft end61of the electric motor30is connected with a not visible input drive end of the planetary gear60. The electric motor30and the planetary gear60are thereby combined into a common unit forming the actuator9,10,11and the output shaft end45of the planetary gear60thereby forms the output shaft of the actuator.

Each actuator9,10,11may be provided with a rotary encoder in order to control the rotational position of the respective cylindrical parts38,39,40. However, it is preferred to use a stepper motor and corresponding motor controller which may detect lost or gained steps and measure motor load and which may use these parameters for self-test diagnostics. A homing function may be made against the first and/or second end stop protrusions48,49in order to initialise the position of the cylindrical part38,39,40. The homing function may employ programmable current control. Thereby, inaccuracies as a result of backlash in the transmission from motor to cylindrical part may be reduced or eliminated.

A not shown computer controlled database system may be adapted to store each of such distinctive rotational positions of the individual indicator element6,7,8as belonging to a corresponding distinctive individual identification pattern to be formed in a casting.

The mounting block17including the insertion portion12, the cylindrical parts38,39,40with the corresponding individually adjustable indicator elements6,7,8and the mounting bracket16may advantageously be produced for instance by micro milling or micro printing. The parts may advantageously be made of metal.

The following embodiments are disclosed:

1. A sand mould identification device1with a housing2including an identification pattern face3adapted to be arranged in a pattern forming surface4of a sand moulding machine5or a core shooter, wherein a plurality of individually adjustable indicator elements6,7,8are arranged rotationally in the identification pattern face3, the rotational position of each individual indicator element being6,7,8adjustable by means of an actuator9,10,11, wherein the housing2includes an insertion portion12adapted to be inserted into a corresponding recess13of said sand moulding machine5or core shooter and having a front end14and a rear end15, wherein the identification pattern face3is located at the front end14of the insertion portion12, wherein at least a part of each actuator9,10,11is inserted into the insertion portion12, and wherein the housing2includes a mounting device for mounting the housing2to the sand moulding machine5or core shooter, characterised in that, in the assembled state of the sand mould identification device1, the insertion portion12is adapted to be inserted into the sand moulding machine5or core shooter in an insertion direction D extending from the rear end15to the front end14of the insertion portion12, and in that the mounting device is accessible at or behind the rear end15of the insertion portion12for mounting or demounting the housing2to or from the sand moulding machine5or core shooter.

2. A sand mould identification device according to embodiment 1, wherein a motor control for the actuators9,10,11and a network adaptor is arranged behind the rear end15of the insertion portion12.

3. A sand mould identification device according to embodiment 1 or 2, wherein the mounting device has the form of a mounting bracket16arranged at or behind the rear end15of the insertion portion12and protruding in relation to the insertion portion12in a direction being transverse to the insertion direction D.

4. A sand mould identification device according to embodiment 3, wherein the insertion portion12forms part of a mounting block17forming protrusions18,19extending in opposed directions at the rear end15of the insertion portion12, and wherein the mounting bracket16is fastened to the respective protrusions18,19preferably by means of bolts20.

5. A sand mould identification device according to embodiment 4, wherein the actuators9,10,11are arranged along a central line21of the mounting block17extending between the opposed protrusions18,19of the mounting block17, wherein the mounting bracket16forms opposed mounting flanges22,23at either side of the central line21of the mounting block17, and wherein the mounting flanges22,23are adapted to be mounted on the sand moulding machine5or core shooter preferably by means of bolts24.

6. A sand mould identification device according to any one of the embodiments 3 to 5, wherein the mounting bracket16includes a first bracket part25and a second bracket part26clamped together and gripping on either side of a part of each actuator9,10,11.

7. A sand mould identification device according to embodiment 6, wherein an elastic element27is sandwiched between the actuators9,10,11and the first and second bracket parts25,26.

8. A sand mould identification device according to embodiment 6 or 7, wherein a printed circuit board28including a motor control and a network adaptor abuts the first and second bracket parts25,26oppositely the insertion portion12.

9. A sand mould identification device according to embodiment 8, wherein a rear end29of an electric motor30of each actuator9,10,11extends through a hole31,32,33in the printed circuit board28.

10. A sand mould identification device according to embodiment 8 or 9, wherein the printed circuit board28is partly covered by a cover34so that an edge35of the printed circuit board28extends from the cover34and is provided with at least one network connector part36.

11. A sand mould identification device according to any one of the preceding embodiments, wherein each individually adjustable indicator element6,7,8is arranged at a front end37of a cylindrical part38,39,40fitting in a corresponding bore41,42,43of the insertion portion12, wherein a rear end44of the cylindrical part38,39,40engages a shaft end45of the corresponding actuator9,10,11, and wherein the cylindrical part38,39,40and/or the corresponding bore41,42,43has a recess46in which a sealing ring47is arranged.

12. A sand mould identification device according to embodiment 11, wherein a first end stop protrusion48is arranged on the cylindrical part38,39,40, and a second corresponding end stop protrusion49is arranged in the corresponding bore41,42,43of the insertion portion12.

13. A sand mould identification device according to embodiment 12, wherein the sealing ring47is arranged between the front end37of the cylindrical part38,39, and the first end stop protrusion48arranged on the cylindrical part.

14. A sand mould identification device according to any one of the embodiments 11 to 13, wherein the rear end44of the cylindrical part38,39,40is provided with a partly cylindrical hole50having an axially extending flat face51corresponding to an axially extending flat face52of the shaft end45of the corresponding actuator9,10,11, and wherein said shaft end45engages the partly cylindrical hole50.

15. A sand mould identification device according to any one of the embodiments 2 to 14, wherein the network adaptor of the sand mould identification device1is adapted to be connected to a controller of a sand moulding machine5by means of a connector53including a first connector part54adapted to be arranged on a pattern plate56of the sand moulding machine5and a second connector part55adapted to be arranged on the sand moulding machine5, wherein each connector part54,55includes a number of electrical contact elements57,58, and wherein the electrical contact elements58of the second connector part55are adapted to flexibly engage and slide on a top side59of the respective electrical contact elements57of the first connector part54during a mounting operation of the pattern plate56on the sand moulding machine5.

16. A sand mould identification device according to any one of the preceding embodiments, wherein the insertion portion12has a cross-sectional dimension CS transversely to the insertion direction D being maximum 30 percent, preferably maximum 20 percent, and most preferred maximum 10 percent larger than a diameter d of the part of the actuator9,10,11inserted into the insertion portion12.

17. A sand moulding machine including at least one sand mould identification device1according to any one of the preceding embodiments.

LIST OF REFERENCE NUMBERS

CS cross-sectional dimension of insertion portiond diameter of part of actuator inserted into insertion portionD insertion direction of insertion portion1sand mould identification device2housing3identification pattern face of housing4pattern forming surface of sand moulding machine or core shooter5sand moulding machine6,7,8individually adjustable indicator element9,10,11actuator12insertion portion of housing13recess of sand moulding machine or core shooter14front end of insertion portion15rear end of insertion portion16mounting bracket17mounting block18,19protrusion of mounting block20bolt for assembly of housing parts21central line of mounting block22,23mounting flange of mounting bracket24mounting bolt for mounting flange25first bracket part26second bracket part27elastic element28printed circuit board29rear end of electric motor30electric motor of actuator31,32,33hole in printed circuit board34cover35edge of printed circuit board36network connector part37front end of cylindrical part38,39,40cylindrical part41,42,43bore of insertion portion44rear end of cylindrical part45shaft end of planetary gear of actuator46recess of cylindrical part or bore47sealing ring48first end stop protrusion of cylindrical part49second end stop protrusion of bore50partly cylindrical hole of rear end of cylindrical part51axially extending flat face of partly cylindrical hole52axially extending flat face of shaft end of actuator53connector54first connector part55second connector part56first pattern plate57electrical contact elements of first connector part58electrical contact elements of second connector part59top side of electrical contact element of first connector part60planetary gear of actuator61shaft end of electrical motor of actuator62clamping bolt for first and second bracket parts63stationary alignment element64set screw for cylindrical part65threaded bore for set screw66through hole for set screw67bore for mounting bolt68threaded bore for assembly bolt69threaded bore for clamping bolt70bore for clamping bolt71recess in cover for mounting bolt72protruding spacer on mounting bracket for printed circuit board73hole in printed circuit board for assembly bolt74bore in mounting bracket for assembly bolt75rounded part of insertion portion76piston for pressing plate77heating plate of sand moulding machine78pressing plate of sand moulding machine79second pattern plate80moulding chamber of sand moulding machine81swing plate of sand moulding machine82pivot axis for swing plate83swing arm for swing plate84sand filling opening in top wall of moulding chamber85bottom wall of moulding chamber86top wall of moulding chamber87front side of pattern plate88back side of pattern plate89network cable90mounting bolt for connector part91relatively broad, partly circular part of individually adjustable indicator element92relatively narrow, elongated part of individually adjustable indicator element