Description:FIELD OF THE INVENTION

[0001] The present invention relates to a vertical centrifugal casting monitoring device that detects color of the molten metal for impurity identification and parallelly monitors and retrieves critical parameters such as temperature and RPM. Additionally, the proposed device ensures the casting process operates within optimal conditions and provide real-time feedback to operators for maintaining high-quality standards and preventing casting defects.

BACKGROUND OF THE INVENTION

[0002] The process of centrifugal casting is widely used in manufacturing castings for various applications. It involves pouring molten metal into a rotating mold, where the centrifugal force ensures uniform distribution of the metal and helps create high-quality components. However, ensuring the purity and correct properties of the molten metal is a challenge, as impurities can compromise the casting's strength and durability.

[0003] Current methods for monitoring the quality of molten metal during centrifugal casting often rely on manual inspection or basic sensors, which can be prone to error and lack the precision needed for critical applications. Additionally, controlling the casting environment, including temperature and rotational speed (RPM), is essential for achieving optimal results, but many existing systems do not provide real-time feedback or integrate various monitoring parameters for comprehensive quality control. Therefore, there is a need for a device that detect impurities in the molten metal, monitor the process parameters, and provide accurate feedback to operators in real time.

[0004] US20050011627A1 discloses about a method and apparatus for centrifugal casting of metal articles uses a rotating mold body that can be pivoted from a vertical orientation to a horizontal orientation during the centrifugal casting of the metal article. The resulting metal article has a closed end and an open end defining a hollow cavity. The mold body has a closed end that is oriented in a vertical position with the longitudinal axis extending vertically. While the mold body is rotated, an amount of molten metal is introduced into the mold body so that the molten metal is distributed along the closed end of the mold body. In one embodiment, the bottom end of the mold body has a frustoconical shaped surface defining the mold cavity. The mold body is then pivoted to a horizontal position while continuously rotating to distribute and cast the metal against the inner surface of the mold body. In one embodiment, the mold body has a refractory lining of a compacted refractory material. The refractory material is introduced into the rotating mold and a blade is contacted with the layer of the refractory material formed on the inner surface while the mold is rotated in a first direction to compact and densify the layer of particles with a flat end of the blade. The rotation of the mold body is then reversed and the sharp edge of the blade is contacted with the compacted layer to shape and contour the mold lining.

[0005] CN201711510U discloses about a centrifugal casting machine, which belongs to the field of centrifugal casting and comprises a centrifugal casting machine main body and a cleaning mechanism, a spraying mechanism, a casting powder addition mechanism and a temperature measurement mechanism matched with the centrifugal casting machine main body. The centrifugal casting machine is characterized in that the machine is also provided with an automatic station switching system for controlling the cleaning mechanism, the spraying mechanism, the casting powder addition mechanism and the temperature measurement mechanism. Through the above scheme, cold cleaning, automatic coating spraying, automatic casting powder addition and accurate automatic temperature measurement can be achieved on the same station. The centrifugal casting machine has compact structure, is simple for operation, and improves the operating efficiency and the workpiece quality.

[0006] Conventionally, many devices have been developed to monitor and control various aspects of the centrifugal casting process, such as temperature regulation, rotational speed, and molten metal quality. However, these systems fail to provide a comprehensive solution that integrates all necessary parameters in real time. Many of the existing devices focus on individual aspects like temperature control or visual inspection, which lead to inefficiencies and the potential for defects in the final cast.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that not only requires to detect the color of the molten metal for impurity identification, but also needs to monitor and retrieve critical parameters such as temperature and RPM. Additionally, the developed device requires to ensure the casting process operates within optimal conditions and provide real-time feedback to operators for maintaining high-quality standards and preventing casting defects.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that detects color of a molten metal poured into a casting machine to identify impurities in order to notify a user if the color deviates from the ideal for the selected metal type and retrieves temperature and RPM parameters to ensure optimal casting conditions, thereby ensuring high-quality casts and minimizing defects.

[0010] Another object of the present invention is to develop a device that detects defects in the cast such as cracks, porosity or voids and projects the affected areas to the user for further inspection and action.

[0011] Yet another object of the present invention is to develop a device that monitors temperature of the molten metal being poured and alerts the user if the temperature falls outside the desired range, thereby preventing formation of defects in the cast.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a vertical centrifugal casting monitoring device that detects color of a molten metal poured into a casting machine to identify impurities in order to notify a user if the color deviates from the ideal for the selected metal type and retrieves temperature and RPM parameters to ensure optimal casting conditions, thereby ensuring high-quality casts and minimizing defects.

[0014] According to an embodiment of the present invention, a vertical centrifugal casting monitoring device, comprises of a cuboidal body positioned on a ground surface placed with a vertical casting centrifugal casting machine to be utilized for manufacturing a cast, a user-interface inbuilt in a computing unit is wirelessly associated with the device accessed by a user to give input commands for monitoring casting operation of the machine and type of molten metal to be used, an artificial intelligence-based imaging unit mounted on the body for detecting exact location of the machine, a motorized tracked wheels configured underneath the body for maneuvering and positioning the body in proximity to the machine, a robotic arm assembled on the body and equipped with a cuboidal unit arranged with a spectral sensor for moving the cuboidal unit around the machine for detecting color of molten metal to be poured in the machine for obtaining a cast, a speaker mounted on the body for notifying the user regarding inaccurate color of the molten metal which indicates impurity of the metal, a database associated with the device that is accessed by the microcontroller for fetching a temperature and RPM (Revolutions Per Minute) of the machine to be maintained during casting processes for the user-defined type of molten metal, the microcontroller activates an IOT-based communication module integrated within the microcontroller for establishing a wireless communication with control unit of the machine to determine the temperature and RPM of the machine, a holographic projection unit mounted on the body for projecting hologram to guide the user regarding the fetched temperature and RPM of the machine to be maintained for optimal casting operation, wherein upon completion of the casting process, as detected via the imaging unit.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a telescopically operated gripper arranged with the body for lifting and placing the cast on a conveyer arranged with the body, an evaluation module installed within the body, wherein the microcontroller actuates the conveyer for translating and positioning the cast within the body, followed by activation of the evaluation module for detecting defects such as cracks, porosity and voids in the cast, and in case of detection of the cracks, the microcontroller activates the projection unit for projecting area of the cast having the defects, an optical flow sensor is configured on the body for detecting flow rate of the molten metal being poured in the machine, a thermal imaging unit mounted on the body for detecting temperature of molten metal being poured for notifying the user to pour the molten metal at an elevated temperature to prevent formation of any cracks in the cast and a battery is associated with the device for supplying power to electrical and electronically operated components associated with the device.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a vertical centrifugal casting monitoring device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a vertical centrifugal casting monitoring device that is capable of detecting color of molten metal poured into a centrifugal casting machine to identify any impurities in the metal. If the color detected does not match the ideal color of the user-defined type of molten metal, the device notifies the user of potential impurities. Additionally, the proposed device retrieves temperature and RPM (Revolutions per Minute) parameters from a database to ensure that the casting process is operating within the optimal conditions required for the selected molten metal type, thereby helping to achieve high-quality casts while preventing defects.

[0022] Referring to Figure 1, an isometric view of a vertical centrifugal casting monitoring device is illustrated, comprising a cuboidal body 101 positioned on a ground surface placed with a vertical casting centrifugal casting machine to be utilized for manufacturing a cast, an artificial intelligence-based imaging unit 102 mounted on the body 101, a robotic arm 104 assembled on the body 101 and equipped with a cuboidal unit 105 arranged with a spectral sensor 106, a speaker 107 mounted on the body 101, a holographic projection unit 108 mounted on the body 101, a telescopically operated gripper 109 arranged with the, a conveyer 110 arranged with the body 101, an evaluation module 111 installed within the body 101, an optical flow sensor 112 configured on the body 101 and a thermal imaging unit 113 mounted on the body 101.

[0023] The proposed device herein comprises of a cuboidal body 101 developed to be positioned on a ground surface, wherein the body 101 is configured with a vertical casting centrifugal casting machine that is to be utilized for manufacturing a cast. The body 101 is made up of but not limited to durable and lightweight materials such as aluminum alloys, stainless steel or high-strength polymers like polycarbonate or ABS plastic. These materials are chosen to provide structural integrity, resistance to corrosion and ease of maneuverability while operating in industrial environments.

[0024] A user-interface is integrated into a computing unit that wirelessly communicates with the device. The user-interface allows a user to input commands to monitor the casting operation of the vertical centrifugal casting machine and specify the type of molten metal to be used for the casting process. The computing unit accessed by the user that includes but is not limited to a smartphone and laptop for enabling the user to provide input.

[0025] The computing unit is linked with a microcontroller embedded with the device via an integrated communication module that includes but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module which is capable of establishing a wireless network between the microcontroller and the computing unit. The computing unit used herein is capable of computing operations according to the user’s desire with the help of the user interface.

[0026] The microcontroller processes input commands received from the user via the computing unit and activates an artificial intelligence-based imaging unit 102 mounted on the body 101 to detect the exact location of the vertical centrifugal casting machine. The imaging unit 102 comprises of an image capturing arrangement including a set of lenses that captures multiple images of the surroundings, and the captured images are stored within a memory of the imaging unit 102 in form of an optical data.

[0027] The imaging unit 102 also comprises of a processor that is integrated with artificial intelligence protocols, such that the processor processes the optical data and extracts the required data from the captured images. The extracted data is further converted into digital pulses and bits and are further transmitted to the microcontroller. The microcontroller processes the received data and to detect the exact location of the vertical centrifugal casting machine.

[0028] Upon detection of the machine, the microcontroller actuates a motorized tracked wheels 103 configured underneath the body 101 for maneuvering and positioning the body 101 in proximity to the machine. The track wheels 103 consist of a durable rubber or polyurethane tread encasing a robust metal or plastic hub, with bearings or bushings facilitating smooth rotation around an axle securely attached to the body’s 101 chassis. This construction enables the track wheels 103 to provide traction and stability on various surfaces, while the tread's grooves or treads enhance grip. Controlled by the microcontroller, the track wheels 103 pivot and maneuver, allowing precise movement of the body 101 towards the machine.

[0029] The microcontroller then actuates a robotic arm 104 assembled on the body 101 and equipped with a cuboidal unit 105 attached with a spectral sensor 106 to move the cuboidal unit 105 around the vertical centrifugal casting machine. The robotic arm 104 is able to perform the designated task with high efficiency and accuracy, wherein the robotic arm 104 consists of mechanical joints and actuators, which are controlled by the microcontroller. The actuators allow various degrees of freedom and movement and the joints are actuated by a DC (Direct Current) motor, providing the necessary force and motion to move the cuboidal unit 105 around the vertical centrifugal casting machine.

[0030] The microcontroller then actuates the spectral sensor 106 to work in synchronization with the imaging unit 102 to detect the color of the molten metal being poured into the vertical centrifugal casting machine. The spectral sensor 106 works by capturing light reflected or emitted from the target material (e.g., molten metal) through its primary components: a light source, an optical filter, a photodetector and a processing unit. The light source illuminates the molten metal, and the light that interacts with the metal is captured by the sensor 106. The filter separates the light into its constituent wavelengths (spectrum), which are then detected by the photodetector.

[0031] This component measures the intensity of each wavelength across the spectrum. The data collected by the photodetector is sent to the microcontroller, which analyzes it to detect specific color or composition characteristics of the molten metal. By comparing the measured spectrum with known reference values, the microcontroller identifies the type and quality of the molten metal, ensuring that it aligns with user-defined specifications for casting.

[0032] If the detected color of the molten metal, as analyzed by the spectral sensor 106, does not match the ideal color corresponding to the user-defined type of metal, then the microcontroller identifies this mismatch as an indication of potential impurities in the metal. The microcontroller then triggers a speaker 107 mounted on the body 101 to alert the user that the molten metal being used is impure, prompting corrective action to be taken to ensure the quality and consistency of the casting process.

[0033] In an embodiment, the device is equipped with a database that stores critical operational parameters including the ideal temperature and RPM (Revolutions per Minute) for the vertical centrifugal casting machine. The microcontroller accesses this database to retrieve the specific temperature and RPM values required for the user-defined type of molten metal being used in the casting process.

[0034] To ensure the machine is operating within these parameters, the microcontroller activates an integrated IoT-based communication module that establishes a wireless connection with the control unit of the casting machine, enabling real-time monitoring and adjustment of the machine’s temperature and RPM. Through this wireless communication, the microcontroller ensures that the machine operates under the optimal conditions necessary for high-quality casting.

[0035] A holographic projection unit 108 is mounted on the body 101 that is activated by the microcontroller to project a hologram that provides real-time guidance to the user, displaying the fetched temperature and RPM values that need to be maintained for optimal casting operation. The hologram serves as a visual aid, ensuring the user is able to easily monitor and adjust the machine's settings for precise and efficient casting.

[0036] The holographic projection unit 108 consists of a light source, a spatial light modulator (SLM), a projection lens and a laser. The light source emits coherent light, which is directed onto the SLM. The SLM modulates the light by altering its phase, amplitude, or color, depending on the input data. This modulated light is then focused and directed through a projection lens, which projects the holographic image into space or onto a surface creating a three-dimensional image. The image appears as a 3D visual representation of the data, which is able to be viewed from different angles, allowing for interactive, real-time displays of information such as measurements.

[0037] Once the casting process is completed as detected by the imaging unit 102, the microcontroller activates a telescopically operated gripper 109 arranged on the body 101 for lifting the completed cast. The telescopically operated gripper 109 is linked to a pneumatic unit, including an air compressor, air cylinders, air valves and piston which works in collaboration to aid in extension and retraction of the gripper 109.

[0038] The pneumatic unit is operated by the microcontroller. Such that the microcontroller actuates valve to allow passage of compressed air from the compressor within the cylinder, the compressed air further develops pressure against the piston and results in pushing and extending the piston. The piston is connected with the gripper 109 and due to applied pressure, the gripper 109 extends and similarly, the microcontroller retracts the gripper 109 by closing the valve resulting in retraction of the piston. Thus, the microcontroller regulates the extension/retraction of the gripper 109 for lifting the completed cast and placing the cast on a conveyor arranged with the body 101.

[0039] The evaluation module 111 is installed within the body 101 that works in synchronization with the microcontroller to inspect the quality of the cast. After the cast is positioned by the conveyer 110, the microcontroller activates the evaluation module 111, which consists of an ultrasonic sensor and an X-ray diffraction unit. The ultrasonic sensor works based on the principle of sound wave reflection.

[0040] The ultrasonic sensor consists of a transmitter that emits high-frequency sound waves (ultrasonic waves) and a receiver that detects the reflected waves. When the sound waves are directed towards the cast, they travel through the material and are reflected back by any internal flaws such as cracks, voids, or irregularities. The sensor measures the time it takes for the waves to return, and by calculating the distance traveled and identify the location and size of the defect. The differences in the reflected waves’ characteristics (such as intensity or timing) help the sensor detect the nature and extent of internal flaws.

[0041] The X-ray diffraction unit operates based on the diffraction of X-rays through the material’s crystal structure. The diffraction unit consists of an X-ray tube that generates X-rays and a detector that measures the diffracted rays. When the X-rays are directed at the cast, they interact with the crystalline structure of the material, causing the rays to scatter at specific angles. The pattern of diffraction is then captured by the detector and analyzed. The diffraction pattern reveals information about the cast’s internal structure, such as any microstructural changes, porosity, or material inconsistencies. This is particularly effective for detecting small defects that is not visible on the surface.

[0042] An optical flow sensor 112 is configured on the body 101 that is activated by the microcontroller for detecting flow rate of the molten metal being poured in the machine. The optical flow sensor 112 works based on the principle of detecting changes in the movement of particles or surfaces within a fluid flow. The flow sensor 112 consists of a light emitter typically an LED, and a photodetector arranged in such a way that the light emitted by the LED reflects off the moving molten metal or any particulate matter within the flow.

[0043] As the molten metal flows, the sensor 112 detects the movement of these particles by measuring the shift in the light patterns caused by their motion. The sensor 112 processes these changes in light intensity or angle to calculate the flow rate. When the flow rate deviates from the desired threshold, the sensor 112 signals the microcontroller, which then activates the speaker 107 to notify the user, prompting them to adjust the flow rate accordingly to ensure optimal pouring of the molten metal.

[0044] A thermal imaging unit 113 is mounted on the body 101 for detecting temperature of molten metal being poured. The thermal imaging unit 113 works by detecting infrared radiation emitted from the molten metal, which is related to its temperature. The thermal imaging unit 113 consists of an infrared sensor and optics that focus the infrared radiation onto the sensor. As the molten metal radiates heat, the sensor absorbs this radiation and converts it into an electrical signal, which is proportional to the temperature of the metal. The detected temperature is then analyzed by the device, and if it falls below a predefined threshold, the microcontroller activates the speaker 107 to notify the user to ensure that the molten metal is poured at the correct temperature, preventing defects like cracks in the cast.

[0045] The device is associated with a battery for providing the required power to the electronically and electrically operated components including the microcontroller, electrically powered sensors, motorized components and alike of the device. The battery within the device is preferably a lithium-ion-battery which is a rechargeable battery and recharges by deriving the required power from an external power source. The derived power is further stored in form of chemical energy within the battery, which when required by the components of the device derive the required energy in the form of electric current for ensuring smooth and proper functioning of the device.

[0046] The present invention works best in the following manner, where initially the user interacts with the device via the user-interface installed within the computing unit that is wirelessly connected to the device to input specific parameters, such as the type of molten metal to be used and the desired casting conditions. The microcontroller is linked to this computing unit that processes input commands and activates the imaging unit 102 to captures and processes images of the surroundings for determining the position of the casting machine. This data allows the device to accurately position the body 101 in proximity to the machine using motorized tracked wheels 103. As molten metal is poured into the casting machine, the robotic arm 104 equipped with the spectral sensor 106 moves around the machine to detect the color of the metal. If the color deviates from the ideal color for the selected metal type, the device alerts the user via a speaker 107, indicating potential impurity in the metal. Simultaneously, the microcontroller accesses the database to fetch the optimal temperature and RPM settings for the casting process, adjusting these parameters via an IoT-based communication module. The holographic projection unit 108 then displays guidance for the user, showing the required temperature and RPM settings. Once the casting is complete, detected by the imaging unit 102, the telescopically operated gripper 109 is used to lift and place the cast onto a conveyor. The evaluation module 111, consisting of ultrasonic sensors and an X-ray diffraction unit, detects any defects, such as cracks or porosity and projects these areas on the hologram, ensuring quality control during the casting operation.

[0047] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , C , Claims:1) A vertical centrifugal casting monitoring device, comprising:

i) a cuboidal body 101 positioned on a ground surface placed with a vertical casting centrifugal casting machine to be utilized for manufacturing a cast, wherein a user-interface inbuilt in a computing unit is wirelessly associated with said device that is accessed by a user to give input commands for monitoring casting operation of said machine and type of molten metal to be used;
ii) a microcontroller integrated with said body 101 and wirelessly linked with said computing unit that processes said input commands and activates an artificial intelligence-based imaging unit 102 paired with a processor mounted on said body 101 for capturing and processing multiple images of surroundings, respectively, for detecting exact location of said machine, wherein said microcontroller directs motorized tracked wheels 103 configured underneath said body 101 for maneuvering and positioning said body 101 in proximity to said machine;
iii) a robotic arm 104 assembled on said body 101 and equipped with a cuboidal unit 105 arranged with a spectral sensor 106 that is actuated by said microcontroller for moving said cuboidal unit 105 around said machine, wherein said spectral sensor 106 works in sync with said imaging unit 102 for detecting color of molten metal to be poured in said machine for obtaining a cast, based on which said microcontroller detecting color of metal being used, and in case said detected color mismatches ideal color of said user-defined type of said molten metal, said microcontroller activates a speaker 107 mounted on said body 101 for notifying said user regarding inaccurate color of said molten metal which indicates impurity of said metal;
iv) a database associated with said device that is accessed by said microcontroller for fetching a temperature and RPM (Revolutions Per Minute) of said machine to be maintained during casting processes for said user-defined type of molten metal, wherein said microcontroller activates an IOT-based communication module integrated within said microcontroller for establishing a wireless communication with control unit of said machine to determine said temperature and RPM of said machine;
v) a holographic projection unit 108 mounted on said body 101 that is activated by said microcontroller for projecting hologram to guide said user regarding said fetched temperature and RPM of said machine to be maintained for optimal casting operation, wherein upon completion of said casting process, as detected via said imaging unit 102, said microcontroller a telescopically operated gripper 109 arranged with said body 101 for lifting and placing said cast on a conveyer 110 arranged with said body 101; and
vi) an evaluation module 111 installed within said body 101, wherein said microcontroller actuates said conveyer 110 for translating and positioning said cast within said body, followed by activation of said evaluation module 111 for detecting defects such as cracks, porosity and voids in said cast, and in case of detection of said cracks, said microcontroller activates said projection unit 108 for projecting area of said cast having said defects.

2) The device as claimed in claim 1, wherein an optical flow sensor 112 is configured on said body 101 that is activated by said microcontroller for detecting flow rate of said molten metal being poured in said machine, and in case said detected flow rate recedes/exceeds a threshold level, said microcontroller activates said speaker 107 for notifying said user to maintain an optimum flow rate for pouring said molten metal.

3) The device as claimed in claim 1, wherein a thermal imaging unit 113 mounted on said body 101 for detecting temperature of molten metal being poured, and in case said detected temperature recedes a threshold limit, said microcontroller activates said speaker 107 for notifying said user to pour said molten metal at an elevated temperature to prevent formation of any cracks in said cast.

4) The device as claimed in claim 1, wherein said evaluation module 111 includes an ultrasonic sensor and an X-ray diffraction unit.

5) The device as claimed in claim 1, wherein said telescopically operated gripper 109 is powered by a pneumatic unit that includes an air compressor, air cylinder, air valves and piston which works in collaboration to aid in extension and retraction of said gripper 109.

6) The device as claimed in claim 1, wherein a battery is associated with said device for supplying power to electrical and electronically operated components associated with said device.