Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated sand casting device that facilitates automated creation of custom metal castings by handling the creation of molds, preparation of metal alloys, pattern engraving, and casting of molten metal into desired shapes, thereby improving efficiency, precision, and consistency in metal casting operation.

BACKGROUND OF THE INVENTION

[0002] In metal casting, molds are made by packing sand around a pattern, which is then filled with molten metal to create the desired part. This process has been in use for long period of time and involves several steps, such as creating a molding box, making the pattern, and manually packing the sand around it. However, this traditional approach has several limitations. As the approach relies on skilled workers to shape and compact the sand properly, and even minor errors lead to defects in the final product. The process is slow and labor-intensive, as each mold needs to be carefully prepared by hand. This makes the approach less efficient, especially for large-scale production, where consistency and speed are crucial. Additionally, the quality of the molds varies depending on the worker's expertise, leading to inconsistencies in the final castings. Also, this method is costly and time-consuming compared to modern alternatives.

[0003] Traditionally, sand casting was a labour-intensive, manual process. Workers carve patterns into sand, often in a two-part mold with a separate top and bottom half. The sand was compacted around the pattern, and molten metal was poured into the mold through a channel, called a sprue. The mold then gets broken to reveal the casting, which required additional finishing processes like cleaning and smoothing. So, people also use molding boxes, mechanical compactors, and pattern-making tools to improve efficiency and consistency. Molding boxes are rectangular frames that hold the sand mixture during the molding process. Patterns, often made of metal, were placed inside these boxes to form the mold cavity. Additionally, tools like sand rammers and squeezers helped compact the sand tightly around the pattern, improving the mold’s stability. But these equipment’s fails to achieve the fine tolerances or surface finishes that modern manufacturing methods provide, limiting its use in high-precision applications.

[0004] JPH06190544A discloses a sand casting device is provided with a molding station for molding the sand mold, a molten metal pouring station for pouring the molten metal in the sand mold, a removing molding flask station for removing the molding flask after casting into the sand mold, a separating station for separating the molding sand and the product after removing the molding flask and the separating device arranged at the separating station. Further, the device is provided with a molten metal pouring detecting means for detecting whether the molten metal is poured or not in the molten metal pouring station, a temp. detecting means for detecting the molding sand temp. after removing the molding flask and a working force control means for enlarging the working force of the separating device at the time of detecting no pouring of the molten metal by the molten metal pouring detecting means and for reducing the working force of the separating device at the time of being high temp. at a prescribed temp. or higher of the molding sand temp. based on the temp. detecting means.

[0005] CN218983063U discloses a sand casting equipment, and discloses a high-efficiency sand casting device, which comprises a cylindrical high-efficiency sand casting machine body, wherein the cylindrical high-efficiency sand casting machine body comprises a sand casting cylinder body, a discharging square pipe and a sealing plug; the mixing mechanism comprises a large-torque motor which is connected to the bottom end of the sand casting barrel body. According to the stirring device, the stirring shaft and the square bar are connected in a sliding mode, so that the stirring shaft can move on the square bar, and meanwhile, the stirring shaft and the square bar can rotate, so that the fork-tooth-shaped stirring frame can rotate up and down in the sand casting barrel.

[0006] Conventionally, many devices have been developed that are capable of casting sand. However, these devices are incapable of performing metal casting to the specific requirements of the user. Additionally, these existing devices also lack in mixing right proportions of metal alloys which causes inconsistent and low-quality alloy for casting.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to allow a user to select a custom design for the desired metal casting, thus ensuring that each casting is made to the specific requirements of the user. In addition, the developed device also needs to automate the preparation and mixing of metal alloys, in view of ensuring right proportions of metals are used to form a consistent and high-quality alloy for casting.

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 is capable of performing casting of sand in a self-sufficient manner in view of reducing manual efforts as well as consumption of time.

[0010] Another object of the present invention is to develop a device that allows a user to select a custom design for the desired metal casting, thus ensuring that each casting is made to the specific requirements of the user.

[0011] Another object of the present invention is to develop a device that accurately positions the mold, for ensuring proper alignment before pouring of molten metal, thus improving the quality of the final product and reducing defects.

[0012] Yet another object of the present invention is to develop a device that automates the preparation and mixing of metal alloys, in view of ensuring right proportions of metals are used to form a consistent and high-quality alloy for casting.

[0013] 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

[0014] The present invention relates to an automated sand casting device that is able to automate the sand casting process to minimize manual effort and time, while enabling the user to choose a custom design for the metal casting, thereby ensuring that each piece is produced according to the user’s specific requirements.

[0015] According to an embodiment of the present invention, an automated sand casting device comprises of a housing developed to be positioned on a fixed surface, the housing is arranged with a touch interactive display panel that is accessed by a user for selecting a user-desired design into which a metal alloy is to be molded, a 3-dimensional printer arranged inside the housing to generate a mold of the user-selected design, an artificial intelligence-based imaging unit is installed inside the housing to determine positioning of the generated mold, a pair of motorized gripper arranged inside the housing for gripping the mold, a multi-sectioned container is arranged on top portion of the housing and integrated with multiple electronically controlled nozzles that dispense an optimum amount of ingredients stored in the container over a mixing tray arranged underneath the container to form a brick of clay, an ultrasonic sensor integrated inside the housing for determining dimensions of the brick, a furnace arranged inside the housing into which different ratio of metals are accommodated, multiple heating units integrated in the furnace to melt the accommodated metal to form molten alloy, a non-contact moisture sensor is integrated inside the housing for determining solidification of the alloy on the brick, and a speaker mounted on the housing to produce audio command for the user to collect the casted alloy from the housing.

[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 a perspective view of an automated sand casting 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 an automated sand casting device that enables the user to choose a custom design for desired metal casting, in view of ensuring that each piece meets the user's specific requirements. Additionally, the proposed device also automates preparation and mixing of metal alloys, for ensuring the correct proportions of metals are used to produce a consistent and high-quality alloy for the casting process.

[0022] Referring to Figure 1, a perspective view of an automated sand casting device is illustrated, respectively, comprising a housing 101 developed to be positioned on a fixed surface, the housing 101 is arranged with a touch interactive display panel 102, a 3-dimensional printer 103 arranged inside the housing 101, an artificial intelligence-based imaging unit 104 is installed inside the housing 101, a pair of motorized gripper 105 arranged inside the housing 101, a multi-sectioned container 106 is arranged on top portion of the housing 101 and integrated with multiple electronically controlled nozzles 107, a mixing tray 108 arranged underneath the container 106, a furnace 109 arranged inside the housing 101, a speaker 110 mounted on the housing 101.

[0023] A housing 101 used herein is developed to be positioned on a fixed surface and comprises of a handy and portable cuboidal enclosure encasing various components associated with the device, wherein the housing 101 is made up of material that includes but not limited to plastic or metal that ensures that the device is of generous size and is light in weight.

[0024] The housing 101 is arranged with a touch interactive display panel 102 which facilitates a user in selecting a user-desired design into which a metal alloy is to be molded. The touch interactive display panel 102 as mentioned herein is typically an LCD (Liquid Crystal Display) screen that presents output in a visible form. The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers.

[0025] A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user inputs details regarding selecting a user-desired design into which a metal alloy is to be molded. A touch controller is typically connected to the microcontroller through various interfaces which may include but are not limited to SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit)

[0026] A 3-dimensional printer 103 is positioned within the housing 101 and is directed by an inbuilt microcontroller to generate a mold based on a user-selected design. The printer 103 utilizes additive manufacturing module, where the material is deposited layer by layer to form the mold according to the specified dimensions and configuration provided by the user. The microcontroller processes the user’s design input and directs the printer 103 to fabricate the mold with precise control over the material deposition, in view of ensuring accuracy and consistency in the mold structure.

[0027] The 3-dimensional printer 103 operates by building up an object layer by layer based on a digital design. The printer 103 uses a material, such as plastic or resin, that is heated or cured as it is deposited to form each layer. The design file, typically in a 3D model format, is processed by the microcontroller, which directs the printers 103 movements and material flow to precisely create the desired shape. The printer 103 follows the instructions in the digital model to produce a mold or object with high accuracy, offering a customizable and efficient method for creating complex shapes as per user desired.

[0028] The microcontroller, mentioned herein, is preferably an Arduino microcontroller. The Arduino microcontroller used herein controls the overall functionality of the components linked to it. The Arduino microcontroller is an open-source programming platform. The microcontroller receives the data from various electronic units and generates a command signal for further processing.

[0029] The housing 101 is installed with an artificial intelligence-based imaging unit 104 which is synchronously actuated by the microcontroller to determine positioning of the generated mold. The imaging unit 104 disclosed herein comprises of an image capturing arrangement including a set of lenses that captures multiple images of inside of the housing 101 and the captured images are stored within memory of the imaging unit 104 in form of an optical data.

[0030] The imaging unit 104 also comprises of the processor which processes the captured images. This pre-processing involves tasks such as noise reduction, image stabilization, or color correction. The processed data is fed into AI protocols for analysis which utilizes machine learning techniques, such as deep learning neural networks, to extract meaningful information from the visual data which are processed by the microcontroller to determine positioning of the generated mold.

[0031] As the position of the mold is determined by the imaging unit 104 the microcontroller generates a command and directs the actuation of a pair of motorized grippers 105 which are arranged inside the housing 101. The motorized grippers 105 operates as a robotic hand that is designed to grasp the mold effectively. The gripper 105 typically incorporates a motorized mechanism that controls the opening and closing of the jaws of the gripper 105. The motor generates the necessary force to move the grippers 105 fingers for the opening and closing of the jaws with precision. This motorized action is often controlled by the microcontroller for the smooth and precise gripping of mold.

[0032] On top portion of the housing 101 a multi-sectioned container 106 is arranged which is stored with ingredients, wherein the container 106 is integrated with multiple electronically controlled nozzles 107 (preferably 2 to 6 in numbers). The electronic nozzles 107 works by utilizing electrical energy to automize the flow of ingredients in a controlled flow pattern by converting the pressure energy of a fluid into kinetic energy. Upon actuation of nozzles 107 by the microcontroller, the electric motor or the pump pressurizes the incoming ingredients, increasing its pressure significantly. High pressure enables the ingredients to be dispensed out with a high force, over a mixing tray 108 which is arranged underneath the container 106 to form a brick of clay.

[0033] The housing 101 is installed with an ultrasonic sensor which determines dimensions of the brick. The ultrasonic sensor works by emitting ultrasonic waves and then measuring the time taken by these waves to bounce back after hitting the surface of the brick. The ultrasonic sensor includes two main parts viz. transmitter, and a receiver. The transmitter sends a short ultrasonic pulse towards the surface of brick which propagates through the air at the speed of sound and reflects back as an echo to the transmitter as the pulse hits the brick The transmitter then detects the reflected eco from the surface of brick and calculations is performed by the sensor based on the time interval between the sending signal and receiving echo to determine the dimensions of the brick.

[0034] The determined data is sent to the microcontroller in a signal form, based on which the microcontroller further process the signal to direct the grippers 105 to position the mold over the brick, after which the grippers 105 press the mold onto the brick, which causing the pattern from the mold to be engraved onto the brick’s surface.

[0035] A furnace 109 is positioned within the housing 101, designed to accommodate varying ratios of metals for the purpose of melting and alloying. The furnace 109 is equipped to receive specific quantities of different metals, which are introduced into the furnace 109 chamber according to the required proportions for the desired alloy composition. The furnace 109 is operated under controlled conditions, where the microcontroller regulates the temperature and environment within the furnace 109 to ensure optimal melting and mixing of the metals.

[0036] This process is essential for creating a homogeneous mixture of metals that meets the specified requirements for the intended application. The furnace 109 construction ensures safe containment of the molten metal, and its design allows for precise control of heating elements to facilitate the accurate fusion of metals, thereby achieving the desired alloy characteristics.

[0037] In synchronization, the microcontroller regulates the actuation of multiple heating units (preferably 2 to 6 in numbers) that are integrated in the furnace 109. The heating unit used herein is preferably a copper coil that generates heat when an electric current passes through the coil. When an electric current runs through a copper wire the electrons come across the resistive forces of the medium’s material, releasing energy that is expended in the form of heat energy.

[0038] The copper coil is properly insulated to prevent any heat loss and also direct the generated heat toward the accommodated metal. The heating unit begins to generate heat and as the heating element melt the accommodated metal to form molten alloy, and that molten alloy is transferred to the engraved pattern to form a user-selected design of the alloy.

[0039] The housing 101 is installed with a non-contact moisture sensor which determines solidification of the alloy on the brick. The non-contact moisture sensor comprises of an infrared emitter and a receiver. On actuation the emitter emits infrared light on the alloy and when the light collides with the alloy, a part of beam is refracted due to moisture and rest of beam is reflected back to a receiver in form of electrical signal and based on which the microcontroller measures the absorbance and reflectance of light to determine the solidification of the alloy on the brick.

[0040] Upon complete solidification, the microcontroller actuates a speaker 110 which is mounted on the housing 101. The speaker 110 disclosed herein works by receiving signals from the microcontroller, converting them into sound waves through a diaphragm’s vibration, and producing audible sounds with the help of amplification and control circuitry in order to produce audio command for the user to collect the casted alloy from the housing 101.

[0041] Moreover, a battery is associated with the device for powering up electrical and electronically operated components associated with the device and supplying a voltage to the components. The battery used herein is preferably a Lithium-ion battery which is a rechargeable unit that demands power supply after getting drained. The battery stores the electric current derived from an external source in the form of chemical energy, which when required by the electronic component of the device, derives the required power from the battery for proper functioning of the device.

[0042] The present invention works best in the following manner, where the housing 101 as disclosed in the invention is developed to be positioned on the fixed surface. Now the housing 101 is arranged with the touch interactive display panel 102 that is accessed by the user for selecting the user-desired design into which the metal alloy is to be molded. Then the 3-dimensional printer 103 arranged inside the housing 101 that is actuated by the inbuilt microcontroller to generate the mold of the user-selected design. Thereafter the artificial intelligence-based imaging unit 104 is installed inside the housing 101 to determine positioning of the generated mold. Afterwards the pair of motorized grippers 105 arranged inside the housing 101 for gripping the mold. Then the multi-sectioned container 106 is arranged on top portion of the housing 101 and integrated with multiple electronically controlled nozzles 107 that dispense the optimum amount of ingredients stored in the container 106 over the mixing tray 108 arranged underneath the container 106 to form the brick of clay. Synchronously, the ultrasonic sensor integrated inside the housing 101 and synced with the imaging unit 104 for determining dimensions of the brick. Accordingly, the gripper 105 accommodates the mold over the brick and simultaneously performs pressing of the mold against the brick which results in engraving of the complementary pattern of the mold onto the brick.

[0043] In continuation, thereafter the furnace 109 arranged inside the housing 101 into which different ratio of metals is accommodated. At the same time followed multiple heating units integrated in the furnace 109 to melt the accommodated metal to form molten alloy. Then the molten alloy is transferred to the engraved pattern to form the user-selected design of the alloy. Further the non-contact moisture sensor is integrated inside the housing 101 for determining solidification of the alloy on the brick. Moreover, the speaker 110 mounted on the housing 101 to produce audio command for the user to collect the casted alloy from the housing 101.

[0044] 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) An automated sand casting device, comprising:

i) a housing 101 developed to be positioned on a fixed surface, wherein said housing 101 is arranged with a touch interactive display panel 102 that is accessed by a user for selecting a user-desired design into which a metal alloy is to be molded;
ii) a 3-dimensional printer 103 arranged inside said housing 101 that is actuated by an inbuilt microcontroller to generate a mold of said user-selected design, wherein an artificial intelligence-based imaging unit 104 is installed inside said housing 101 and integrated with a processor for capturing and processing multiple images of inside of said housing 101, respectively to determine positioning of said generated mold;
iii) a pair of motorized gripper 105 arranged inside said housing 101 that is actuated by said microcontroller in sync with said imaging unit 104 for gripping said mold, wherein a multi-sectioned container 106 is arranged on top portion of said housing 101 and integrated with multiple electronically controlled nozzles 107 that are actuated by said microcontroller to dispense an optimum amount of ingredients stored in said container 106 over a mixing tray 108 arranged underneath said container 106 to form a brick of clay;
iv) an ultrasonic sensor integrated inside said housing 101 and synced with said imaging unit 104 for determining dimensions of said brick, in accordance to which said microcontroller directs said gripper 105 to accommodate said mold over said brick, followed by pressing of said mold by said gripper 105 against said brick which results in engraving of a complementary pattern of said mold onto said brick; and
v) a furnace 109 arranged inside said housing 101 into which different ratio of metals is accommodated, followed by actuation of multiple heating units integrated in said furnace 109 to melt said accommodated metal to form molten alloy, wherein said molten alloy is transferred to said engraved pattern to form a user-selected design of said alloy.

2) The device as claimed in claim 1, wherein a non-contact moisture sensor is integrated inside said housing 101 for determining solidification of said alloy on said brick.

3) The device as claimed in claim 1 and 2, wherein upon complete solidification, said microcontroller actuates a speaker 110 mounted on said housing 101 to produce audio command for said user to collect said casted alloy from said housing 101.