BACKGROUND

FIELD OF THE INVENTION

The present invention generally relates to a mould inspection system. More particularly, the invention relates to an automated system for identifying defective moulds.

DESCRIPTION OF THE RELATED ART

Casting is a very widely used manufacturing process for a wide range of components. Casting usually involves pouring of hot molten material (usually metal) into a specifically designed mould. The mould is designed to specific size and dimensions of the components. Traditionally, the mould is made of a ceramic material or minerals. After the poured metal cools down and solidifies, the mould is broken to obtain final casting of a component. It is very important for the mould to be able to withstand the thermal stresses created due to the hot molten material else the final casting obtained will not possess the desired dimensions or mechanical properties. This becomes even more important in sand casting, where the mould is made of sand. In the sand casting, the mould is susceptible to damage when hot metal is poured. Hence, there exists a clear need to evaluate whether a mould has the required mechanical properties or not, and to avoid using faulty moulds which are not up to the desired standards.

Currently, the fault detection of moulds is done manually by testing each mould on an assembly line over properties including but not limited to- mould hardness, strength, permeability, and moisture content. If the measured properties are outside the desired range, the mould is deemed unfit and is removed from the assembly line otherwise it is used for casting. The entire existing process is slow, cumbersome, and prone to human error, thereby resulting in poor quality control. From the foregoing, there exists a need for an automated system that can automatically detect faulty moulds with high precision at a large-scale production.

OBJECTS OF THE INVENTION

An object of the present invention is to develop an automated fault detection system for moulds to reduce time for inspection of the moulds.

Yet another object of the present invention is to develop the automated fault detection system for moulds to eliminate human error and enhance inspection quality in identifying faulty moulds.

Yet another object of the present invention is to develop the automated fault detection system for identifying faulty moulds on a large scale.

SUMMARY OF THE INVENTION

The present invention discloses a system for inspecting a plurality of moulds. The system includes a conveyor, a detection unit, and a control unit. The conveyer is used for transporting the plurality of moulds along a predetermined path. The detection unit is disposed in the predetermined path for inspecting each mould of the plurality of moulds travelling in the predetermined path. The control unit is coupled to the detection unit for manoeuvring the detection unit onto each mould of the plurality of moulds and receiving data from the detection unit. Moreover, the control unit identifies one or more faulty moulds from the plurality of moulds using the data received from the detection unit. The The system further includes a marker unit that is disposed after the detection unit along the predetermined path and coupled to the control unit for marking the one or more faulty moulds with a corresponding identification mark. The system includes first and second proximity sensors that are positioned in the predetermined path and coupled to the control unit for identifying position of each mould of the plurality of moulds in proximity to the detection unit. The system may further include a sorting unit that is disposed after the detection unit along the predetermined path for selectively segregating the one or more faulty moulds from the predetermined path. The system reduces inspection time of the plurality of moulds and eliminates human error.

BRIEF DESCRIPTION OF DRAWINGS

The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. Embodiments of the present invention will herein after be described in conjunction with the appended drawings provided to illustrate and not to limit the scope of the claims, wherein like designations denote like elements, and in which:

Fig. 1A is an isometric view of an automated fault detection system for moulds, in accordance with an embodiment of the present invention;

Fig. 1B is a side view of the automated fault detection system for the moulds, in accordance with an embodiment of the present invention; and

Fig. 2 is a flow chart that illustrates a method for inspecting the moulds, in accordance with an embodiment of the present invention.

PET ATT ED DESCRIPTION OF EMBODIMENTS

As used in the specification and claims, the singular forms“a”,“an” and“the” include plural references unless the context clearly dictates otherwise. For example, the term“an article” may include a plurality of articles unless the context clearly dictates otherwise.

Those with ordinary skill in the art will appreciate that the elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated, relative to other elements, in order to improve the understanding of the present invention. There may be additional components described in the foregoing application that are not depicted on one of the described drawings. In the event such a component is described, but not depicted in a drawing, the absence of such a drawing should not be considered as an omission of such design from the specification.

Before describing the present invention in detail, it should be observed that the present invention constitutes an on-line detection and evaluation system for moulds. Accordingly, the components have been represented, showing only specific details that are pertinent for an understanding of the present invention so as not to obscure the disclosure with details that will be readily apparent to those with ordinary skill in the art having the benefit of the description herein.

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention.

An automated mould fault detection system 100 according to the present invention is shown in Figs. 1 A and 1B. The automated mould fault detection system 100 is an on-line detection and evaluation system for moulds. As shown in Figs. 1A and 1B, the system 100 includes a conveyor 102, an inspection station 104, a control unit 106, and a marker unit 108.

The conveyor 102 transports a plurality of moulds l lOa-l lOc to the inspection station 104 along a predetermined path. The conveyor 102 may operate to feed the plurality of moulds l lOa-l lOc to the inspection station 104 at a predetermined speed. The conveyor 102 may receive the plurality of moulds l lOa-l lOc from a mould making machine (not shown). In an embodiment, the mould making machine may work synchronously with the system 100 to deliver the plurality of moulds l lOa-l lOc. The plurality of moulds l lOa-l lOc may be fed onto the conveyor 102 by any convenient mechanism known in the art such that the plurality of moulds 110a- 11 Oc advance in succession at evenly spaced intervals. The plurality of moulds l lOa-l lOc are thus moved by the conveyor 102 along the predetermined path. The conveyor 102 may be coupled to the control unit 106 such that the control unit 106 may control the movement of the conveyor 102. In an embodiment, each mould of the plurality of moulds l lOa-l lOc may be positioned on a pellet that is transported on the conveyor 102.

The inspection station 104 is disposed in the predetermined path of the conveyor 102. The inspection station 104 includes a support structure 112, a detection unit 114, and a guiding member 116 coupled to the detection unit 114. The support structure 112 is positioned adjacent to the conveyor 102 at a position along the predetermined path. The support structure 112 holds the detection unit 114 with the guiding member 116. The guiding member 116 allows movement of the detection unit 114 onto each mould of the plurality of moulds l lOa-l lOc. Further, the detection unit 114 and the guiding member 116 are coupled to the control unit 106. In an embodiment, the detection unit 114 may be a device that measures at least one of hardness, strength, permeability, or moisture content of each mould of the plurality of moulds l lOa-l lOc. The detection unit 114, which is supported by the support structure 112, may measures combination of parameters, such as hardness, strength, permeability, and moisture content of each mould of the plurality of moulds l lOa-l lOc. The guiding member 116 may include any mechanism that allows its movement in any of three axes directions. In an embodiment, the system 100 may include a mould counter (not shown) disposed at the inspection station 104 and coupled to the control unit 106. The mould counter counts the number of moulds that pass through the inspection station 104.

In an embodiment, the system 100 may include first and second proximity sensors 118A and 118B that are positioned at positions Pl and P2 along a platform of the conveyor 102. The first and second proximity sensors 118 A and 118B sense the position of each mould of the plurality of moulds l lOa-l lOc that move towards the inspection station 104 along the conveyor 102. The control unit 106 is coupled to the conveyor 102 and the first and second proximity sensors 118A-118B. The first and second proximity sensors 118A- 118B sense the position of each mould of the plurality of moulds l lOa-l lOc and sends signals to the control unit 106. Once the control unit 106 receives the signals from the first and second proximity sensors 118A-118B, the control unit 106 stalls the conveyor 102 such that a mould of the plurality of moulds 110a- 110c is positioned at the inspection station in proximity of the positions Pl and P2. The control unit 106 then controls the guiding member 116 to guide the detection unit 114 onto the mould of the plurality of moulds l lOa-l lOc. The control unit 106 manoeuvres the guiding member 116 in order to position the detection unit 114 at a prerequisite location on the mould. Once the guiding member 116 positions the detection unit 114 onto the mould, the control unit 106 actuates the detection unit for determining one or more parameters of the mould of the plurality of moulds l lOa-l lOc. In another embodiment, the control unit 106 controls the conveyor 102 so that the conveyor 102 can be halted at any predetermined position along the predetermined path.

For example, the detection unit 114 may be a hardness tester that measures hardness of the mould of the plurality of moulds l lOa-l lOc. The hardness test has an indenter (not shown) that engages with a surface of the mould of the plurality of moulds l lOa-l lOc to measure the hardness at one or more positions on the mould. The control unit 106 controls the movement of the detection unit 114 through the guiding member 116 such that the detection unit 114 can be positioned at one or more positions on the mould to determine requisite parameters of the mould. The detection unit 114 sends data related to measured parameters of the mould to the control unit 106.

The control unit 106 receives the data from the detection unit 114. As shown in Fig. 1B, the control unit 106 includes an evaluation means 120 that evaluates co-relation between identified data by the detection unit 114 and corresponding threshold data. Moreover, the evaluation means also determines a faulty state of the mould based on analysed data. If the measured parameter values are between predetermined upper and lower threshold values, the mould is deemed to be fit by the evaluation means 120. However, if any of the measured parameter values are not between the predetermined upper and lower threshold values, the mould is deemed to be faulty by the evaluation means 120. In an embodiment, the evaluation means 120 may be a software that is suitably programmed to user requirements. The evaluation means 120 also determines fault type and the number of faults for each mould of the plurality of moulds 1 lOa-l lOc.

The control unit 106 further includes a registering means 122 that receives the analysed data from the evaluation means 120. The registering means 122 registers faulty condition of the mould of the plurality of moulds l lOa-l lOc. The detected data and the analysed data may be stored electronically or on cloud platform for retrieval or automated analysis by the registering means 122 of the control unit 106. The registering means 122 may process the detected data and the analysed data to obtain overall status of faulty condition and derive the statistics and information for manufacturer. The generated information may instantaneously or later be processed and forwarded to a production personnel for possible corrective measures at the mould making machine.

The conveyor 102 transports the mould of the plurality of moulds l lOa-l lOc from the inspection station 102 to the market unit 108. The conveyor 102 delivers the mould to the marker unit 108 once the mould is inspected at the inspection station 102. The marker unit 108 is disposed after the inspection station 102 along the predetermined path and coupled to the control unit 106. The registering means 122 may generate a signal if the mould is deemed to be faulty. The control unit 106 actuates the marker unit 108 based on the signal generated by the registering means 122. If the mould is not faulty, the registering means 122 may not generate any signal to the control unit 106 for actuation of the marker unit 108. In an embodiment, the marker unit 108 may mark a colour on the mould if it is faulty. In another embodiment, the marker unit 108 may create an indentation on surface of the mould if it is faulty. The marker unit 108 allows easy identification of a faulty mould through a visual marker be it the colour or the indentation. In an embodiment, the mould which can be easily identified by a visual inspection of user, are manually taken off the conveyor 102 by an operator. In another embodiment, after the visual marker is created on the mould of the plurality of moulds 1 lOa-l lOc, the mould may then be transported further down by the conveyor 102.

The system 100 may optionally include a sorting unit 124 that is disposed after the marker unit 108 along the predetermined path. The sorting unit 124 may operate independently from the control unit 106. The sorting unit 124 may automatically segregate and reject a faulty mould from the plurality of moulds 1 lOa-l lOc. The sorting unit 124 can identify a faulty mould with the visual marker without human intervention. The sorting unit 124 has a sensing system (not shown) that includes colour sensors, sensors for detecting an indentation (may include optical, ultrasonic or any other sensor) or any other visual marker sensing system. If the visual marker is present, the sorting unit 124 pushes the mould by actuation of a piston cylinder to move it onto a sub-conveyor 126, otherwise the mould is directed along the conveyor 102. A mould that is present on the sub-conveyor 126 may be disposed or fixed. Moulds without visual markers are transported by the conveyor 102 to a delivery station. These moulds can be used in further stages of casting. In an embodiment, the sorting unit 124 may be coupled with the control unit 106.

In an embodiment, the system 100 that is synchronized with the mould making machine to acquire data related to identification pattern or die with which mould is being prepared. In another embodiment, the system 100 can acquire data related to identification pattern or die from user through buttons or HMI (human machine interface). Moreover, the system 100 can store data related to evaluation of mould along with other probable variables, such as time and date stamp, operator ID, and the like.

Referring now to FIG. 2, a flowchart 200 that illustrates a method for identifying and sorting one or more faulty moulds from a plurality of moulds, in accordance with an embodiment of the present invention is shown.

At step 202, the conveyor 102 transports a mould to the inspection station 104 in the predetermined path. At step 204, the detection unit 114 identifies data related to at least one of hardness, strength, permeability, and moisture content of the mould. At step 206, the control unit 106 receives the data from the detection unit 114. The evaluation means 120 of the control unit 106 evaluates the data received from the detection unit 114. At step 208, the control unit 106 determines whether the mould is faulty or not. If at step 208, it is determined that the mould is faulty, the step 210 is performed. If at step 208, it is determined that the mould is not faulty, the step 212 is performed.

At step 210, the marker unit 108 receives signals from the control unit 106 to create a visual mark on the mould to indicate that the mould is faulty. At step 212, the sorting unit 124 receives the mould from the market unit 108 through the conveyor 102. At step 214, the sorting unit 124 inspects the mould for the visual mark. If at step 214, it is determined that the mould has the visual mark, the step 216 is performed. At step 216, the mould is pushed onto the sub-conveyor 126 by the sorting unit 124. If at step 214, it is determined that the mould does not have the visual mark, the step 218 is performed. At step 218, the mould is allowed to continue on the conveyor 102 for further stages of casting.

The automated mould fault detection system 100 has several advantages over the existing techniques for identifying and sorting faulty moulds. The system 100 is faster, less error prone, and scalable than existing manual fault detection techniques. The system 100 also provides valuable data, regarding a large batch of incoming moulds, which can be used to improve manufacturing process of moulds and to perform statistical quality analysis. The system 100 greatly reduces time for inspection of moulds. Further, the system 100 is very flexible and easily adjustable to requirements as the system 100 allows measuring various parameters of moulds by interchanging the detection unit 114.

The present invention has been described herein with reference to a particular embodiment for a particular application. Although selected embodiments have been illustrated and described in detail, it may be understood that various substitutions and alterations are possible. Those having ordinary skill in the art and access to the present teachings may recognize additional various substitutions and alterations are also possible without departing from the spirit and scope of the present invention.