JP6990131B2 - Production control method for castings, production control method for high-mix castings - Google Patents

Description

The present invention relates to a method for controlling production of a cast product.

Conventionally, in the technique described in Patent Document 1, a plurality of types of cast products discharged from a bulk shop are sorted and stored in a predetermined number of unfinished product cases 13 set according to the product. A method of finishing each product in the finishing process, re-storing it in the finished product case 14, and then inputting the number of each of a non-defective product and a defective product into a database for management is disclosed.

Japanese Unexamined Patent Publication No. 2001-321928

Here, many defective products generated in the actual manufacturing process may be shipped as non-defective products if they are reprocessed and then re-inspected and determined to be non-defective products. However, Patent Document 1 does not disclose the management of defective products as reprocessed products.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a production control method for a cast product that can be managed with an appropriate product pallet even when a defective product is determined to be a good product by reprocessing. And.

In order to achieve the above object, the present invention is a production control method for a cast product, which is manufactured by injecting a molten metal distributed from a melting furnace into a ladle and then sequentially pouring the molten metal into a conveyed mold. ,
A molding process of forming a mold with an identification symbol for identifying a ladle on the surface forming the cavity of the casting, and
A sorting process in which the casting taken out from the mold is compared with the quality standard and placed in a predetermined product pallet based on the identification symbol transferred to the casting satisfying the quality standard.
The identification information acquisition process for acquiring the data of the identification code of the cast product sorted by associating it with the identification code attached to the product pallet, and the identification information acquisition process.
Have,
The finishing process for processing castings that do not meet the above quality standards,
When the processed casting is compared with the quality standard and the quality standard is satisfied, the re-sorting process for identifying and storing the corresponding product pallet based on the information acquired in the identification information acquisition process from the identification symbol of the casting, and the re-sorting process.
Have.

Therefore, if a cast product that does not meet the quality standards (hereinafter referred to as a defective product) is reprocessed to become a cast product that satisfies the quality standards (hereinafter referred to as a good reprocessed product), this good reprocessed product is referred to. By storing the product in a product pallet having an identification number associated with the identification number attached to the non-defective product, the relationship between the product pallet and the pan can be maintained, and appropriate production control can be realized.

It is a schematic diagram which shows the casting process of the ductile casting of Example 1. FIG. It is a schematic diagram which shows the sand mold manufacturing process of Example 1. FIG. It is a schematic diagram which shows the sand mold manufacturing process of Example 1. FIG. It is a schematic diagram which shows the sand mold manufacturing process of Example 1. FIG. It is a figure which shows the marking material of the character string for casting of Example 1. FIG. It is a partial cross-sectional view of the convex alphabet and numbers in the 1st marking material of Example 1. FIG. FIG. 3 is a partial cross-sectional view of a truncated cone-shaped dot symbol in the second marking material of Example 1. It is a block diagram in the case of changing the number of dot symbols by cutting of Example 1 with a robot. It is an enlarged view which shows the cutting process of the 2nd marking material of Example 1. FIG. It is a figure which shows the state which cut a part of the dot of Example 1. FIG. It is a characteristic figure which shows the visibility of the dot symbol after casting of the ductile casting of Example 1. FIG. It is a characteristic diagram which shows the visibility between the dot symbols after casting of the ductile casting of Example 1. FIG. It is a flowchart which shows the manufacturing data management method of Example 1. FIG. It is a flowchart which shows the manufacturing data management method of Example 1. FIG. It is a flowchart which shows the sand treatment of Example 1. FIG. It is a flowchart which shows the molten metal process of Example 1. FIG. It is a flowchart which shows the identification symbol change process of Example 1. FIG. It is a process chart which shows the manufacturing process of Example 1. FIG. It is a casting condition data sample of Example 1. It is a flowchart which shows the quality factor effect analysis process of Example 1. FIG. It is a flowchart which shows the analysis process when the product which has the problem of strength comes out in the quality factor effect analysis process of Example 1. FIG. It is a figure which shows the structure of the data associated with the product pallet of Example 1. FIG. It is a flowchart which shows the manufacturing data management method of Example 2. It is an example of a product provided with a marking material area in another embodiment. This is an example of taking a large number of products having a marking material area in another embodiment.

[Example 1]
FIG. 1 is a schematic view showing a casting process of the ductile casting of Example 1. The upper part of FIG. 1 shows the molten metal manufacturing process, the interruption shows the pouring process, and the lower part shows the sand mold manufacturing process.
In the molten metal manufacturing step, the molten metal containing iron as a main component is produced in the melting furnace 30, and is subdivided into a ladle for processing 31a. Then, using the adjusting device 32, a spheroidizing agent such as Mg and an inoculant such as Mn and Cu are added to the treatment ladle 31a to adjust the chemical composition, and the chemical composition is adjusted and then poured into the hot water ladle 31. Move to the specified position on the production line to be poured.

The lower part of FIG. 1 and FIGS. 2 to 4 are schematic views showing the sand mold manufacturing process of the first embodiment. In the sand mold manufacturing process, after installing the lower main mold 10d in the lower mold 100, sand is filled to create the lower sand mold 102. Similarly, after installing the upper main mold 10u and the sprue mold in the upper mold 101, as shown in FIG. 2, the marking material described later is attached to the upper main mold 10u, and sand is filled to form the sprue 11. The upper sand mold 103 provided is created. At this time, as shown in FIG. 3, the information formed on the marking material is transferred to the upper sand mold 103 as an uneven shape. Then, as shown in FIG. 4, the sand mold 104 is manufactured by superimposing the upper sand mold 103 on the lower sand mold 102. Hereinafter, the upper main type 10u and the lower main type 10d are collectively referred to as the main type 10.

In the hot water pouring step, the sand mold 104 is placed on the production line, and when the pouring from the ladle 31 to the sprue 11 is completed, the next sand mold 104 is conveyed and the hot water is poured from the ladle 31. The time from the start of pouring into a certain sand mold 104 to the start of pouring into the next sand mold 104 is called takt time. After the pouring process is completed and cooled, the sand mold 104 is broken, the ductile casting is taken out, and unnecessary parts such as the sprue 11 are removed and molded into a product.

The ductile casting of Example 1 is given an identification symbol that can identify the product by casting. The casting character as an identification symbol for ductile castings is the cause when a defect occurs in the manufacturing process by registering the association between each casting product and its manufacturing process information, inspection information, etc. in the database. Can be easily clarified, and defect response can be speeded up. In addition, the final product on the market also has a function to realize traceability based on the identification symbol cast on the cast product.

FIG. 5 is a diagram showing a marking material for a character string for casting according to the first embodiment. The casting character string of Example 1 is a dot symbol that combines letters consisting of alphabets and numbers assuming daily lot management, etc., and dots, which are special symbols that can be subdivided and managed for each ladle. It is configured in combination with. Here, the dot is a protruding portion erected from a flat surface portion in a truncated cone shape, and the dot symbol is a combination of a plurality of dots (hereinafter, also referred to as a dot group). The character string consisting of the alphabet, numbers, and dots (hereinafter referred to as an identification symbol) is formed by the marking material of the resin plate. The marking material includes a first marking material 1 for casting alphabets and numbers, and a second marking material 2 for casting dot symbols. Here, the character shown in the first marking material 1 represents a generally shared recognizable symbol regardless of a specific rule, and the symbol shown in the second marking material 2 can be recognized by a special rule. Represents a symbol or special character. This marking material is pre-attached to the cavity surface of the main mold for forming the cast sand mold with an adhesive. As a result, since the identification symbol is stamped at the time of sand molding, the character peripheral portion can be molded without losing its shape, and as a result, the accuracy of casting the character string into the cast product can be improved. In Example 1, the marking material is shown as an example in which the first marking material and the second marking material 2 displaying alphabets and numbers are integrally configured, but the alphabet, numbers, and dot symbols are used as individual marking materials. Each may be independently pasted on the main mold.

FIG. 6 is a partial cross-sectional view of convex alphabets and numbers in the first marking material of Example 1 (between A and A'in FIG. 5), and FIG. 7 is a truncated cone-shaped dot in the second marking material of Example 1. It is a partial cross-sectional view (between BB'in FIG. 5) of a symbol. As shown in FIG. 6, the character string portion of the first marking material 1 has a convex shape having a height h1 in a cross section. This truncated cone shape has a tapered shape toward the tip. This is because if the inclination angle θ of the cone is made larger than 70 degrees and the cone is brought closer to a rectangular parallelepiped, the shape of the dots is likely to collapse during transfer to the sand mold. That is, by forming the shape into a truncated cone shape, the formability at the time of sand molding and the hot water circulation at the time of casting are improved.

Further, as shown in FIG. 7, the second marking material 2 is formed into a plate-shaped base portion 2a that holds the dot symbol portion and a position that protrudes outward from the base portion 2a at the four corners of the base portion 2a and is tapered. It has a dot 2b having a surface 2s and a dot 2b. As a result, even when a plurality of dots are formed in a narrow area of several centimeters or less, the pattern can be easily changed by excision, and the pattern of the dots 2b can be stably changed. Further, although the dots 2b are circular in a plan view, they may be polygonal. This is because even if it is a polygon, the shape of the dots after casting becomes a truncated cone shape due to the influence of the flow of hot water. Further, the size of the special symbol formed from the plurality of dots 2b is formed to be substantially equal to the size of one character formed on the first marking material 1. That is, since the dots, which are special characters, are formed in the same range (area) as a plurality of characters, the pasting area becomes small. Therefore, even if the mother die has a limited sticking surface, the degree of freedom in selecting the sticking position is increased.

Further, the thickness of the base portion 2a is set to h4. The dots 2b have a trapezoidal shape with a height h2 in cross section. The height h2 is set to a height at which the difference between the height before cutting the dot 2b and the height after cutting the dot 2b can be sufficiently visually recognized after casting. The dot 2b has a hollow inside, and has a hollow inner peripheral wall 2b2 and a hollow ceiling wall 2b1.

The height of the hollow ceiling wall 2b1 is h3. The thickness h4 of the base portion 2a is formed to be lower than the height h3 of the hollow ceiling wall 2b1 and has a relationship of h2> h3> h4. FIG. 10 is a diagram showing a state in which a part of the dots of the first embodiment is cut off. As shown in FIG. 10, a part of the dots is cut off and disappeared, and the disappeared number (may be the remaining number) is counted or recognized by pattern recognition. Therefore, when cutting the dot 2b, even if the cutting position varies, the height after cutting the dot is 0 because the inside of the dot is hollow. As a result, the variation in the thickness of the dots after cutting can be significantly reduced, and the presence or absence of the dot pattern change can be easily confirmed. Further, at the time of casting, it is possible to suppress the flow of hot water to the sand mold formed by the dots after cutting. That is, if the height of the dots is not sufficiently changed due to the variation in the cutting position, the dots may remain in the sand mold and the hot water may flow. On the other hand, since the inside of the dot is hollow, the height of the dot after cutting becomes 0, the dot does not remain in the sand mold, and the difference in the height of the dot after casting can be clarified. As a result, quality defects when changing the dot pattern can be suppressed, and stable quality of ductile cast products can be ensured.

Further, the tip 2c of the dot of the first embodiment has a flat shape, and a stable dot shape is secured by avoiding an excessively thin portion. The dot symbol of the second marking material 2 can be easily changed from the display of the special symbol by cutting a predetermined portion of the dot symbol every time the molten metal is subdivided (distributed) into the ladle 31, for example. Therefore, the identification symbol can be changed for each ladle 31.

In particular, in the case of a large number of castings in which a plurality of cast products are cast in one casting mold, it is necessary to change the identification symbols of all the cast products according to the takt time of manufacturing. If the marking material 2 is reattached every time the ladle 31 is changed, it takes time to reattach a large number of marking materials 2 and it is not possible to meet the tact time, so that the production efficiency of the production line is increased. Is difficult to improve. On the other hand, if only one dot of the dot symbol is cut, all the identification symbols can be changed in a short time even if a large number of dots are taken, and the tact time is not affected. It is very advantageous in terms of manufacturing efficiency.

FIG. 8 is a configuration diagram in which the number of dot symbols is changed by cutting in Example 1, and FIG. 9 is an enlarged view showing a cutting process of the second marking material in Example 1. A cutting hand 105 is attached to the tip of the robot RB. The cutting hand 105 of the first embodiment is a scissors type, a cutter type, or the like, and has a function of cutting dots. The operating state of the robot RB is controlled by the robot computer RC. The robot computer RC executes a cutting process for the dot symbol of the second marking material 2 to be cut based on a command from the production control computer MC. As a result, the display of the identification symbol is changed by cutting a part of the second marking material 2 attached to each cavity surface of the lower mold 100.

FIG. 11 is a characteristic diagram showing the visibility of the dot symbol after casting the ductile casting of Example 1. The horizontal axis represents the diameter W of the dot symbol of the second marking material 2 before casting (see FIG. 7), and the vertical axis represents the diameter W of the dot symbol after casting. In the casting step of Example 1, the second marking material 2 made of a resin plate is attached to the lower mold 100, and the character shape is transferred to the sand mold. Next, the molten metal is poured from the pouring ladle into a sand mold, cooled, and then the sand is removed, and blasting and finishing are performed. After going through these casting processes, it was examined whether or not legibility could be ensured. According to this, unlike alphabets and numbers, the dot symbol is required to have the flowability of molten metal into a closed space (hole) and blast resistance, so the diameter W of the dots of the second marking material 2 is required to ensure visibility. , 1.8mm was grasped. In other words, when the diameter W is less than 1.8 mm, it was confirmed that the diameter W of the dot symbol after casting deteriorates severely and sufficient visibility cannot be ensured.

FIG. 12 is a characteristic diagram showing the visibility between the dot symbols after casting the ductile casting of Example 1. The horizontal axis represents the space between the dot symbols of the second marking material 2 before casting, and the vertical axis represents the space between the dot symbols after casting. After going through the casting process described in FIG. 7, it was examined whether or not the legibility of the dot symbol spacing after casting with respect to the dot symbol spacing of the second marking material 2 could be ensured. According to this, it was found that the distance between the dot symbols that need to ensure the visibility of each dot symbol after casting should be designed to be 0.45 mm or more. In other words, it was confirmed that when the spacing is less than 0.45 mm, the spacing between the dot symbols after casting is severely deteriorated and sufficient visibility cannot be ensured.

13 and 14 are flowcharts showing the manufacturing data management method of Example 1, FIG. 18 is a process chart showing the manufacturing process of Example 1, and FIG. 19 is a casting condition data sample of Example 1.
In step S1, the production control computer MC formulates and registers a production plan for various products for one day. Specifically, detailed production plan information for each ladle, such as a product number and an identification number corresponding to each ladle 31, a corresponding production amount, a production time, etc., is formulated and a production instruction is given.
In step S2, the first and second marking materials 1 and 2 are molded according to the instructions from the production control computer MC based on the drafted production plan. Specifically, the product number and the identification number are molded into the first marking material 1 consisting of alphabets and numbers and the second marking material 2 consisting of dot symbols by the numbering equipment, and the first marking material 1 is used as the identification symbol. Combine with the second marking material 2 and attach it to the cavity surface of the main mold in advance. At this time, the product number / identification number information (1) is output to the production control computer MC.

In step S3, a sand treatment is performed in which a predetermined additive or the like is added to the sand used for the sand mold and stirred.
FIG. 15 is a flowchart showing the sand treatment of the first embodiment.
In step S31, fresh sand, additives, and water are added to the regenerated sand and kneaded.
In step S32, the compressive strength and the CB value (compactability) are analyzed.
In step S33, the manufacturing data (3) of the analysis value of step S32 and the sand mold processing conditions (processing amount, processing start time, additive information, kneading information, etc.) is output to the production control computer MC.

In step S4, a sand mold is produced on the production line using the main mold to which the identification symbol of step S2 is attached and the sand processed in step S3.
In step S5, the core is inserted into the sand mold as needed, and the sand mold (mold) is moved to a predetermined position on the production line to be poured. The manufacturing information (3) of the sand mold and the core is recorded in the database (external record) in association with the identification symbol of the main mold.

In step S6, the molten metal treatment is performed. FIG. 16 is a flowchart showing the molten metal treatment of Example 1.
In step S61, a molten metal containing iron as a main component is prepared in a melting furnace (main hot water).
In step S62, the principal component analysis (Fe, C, etc.) is performed.
In step S63, the hot water is discharged and the production record information (hot water discharge time, hot water temperature, main component information, etc.) of the original hot water is output to the production control computer MC as manufacturing data (2).
In step S64, the spheroidizing treatment agent and the inoculator are added to the ladle 31 to be treated. Specifically, according to the production plan, the molten metal containing iron as the main component in the melting furnace 30 is divided into small portions and transferred to a ladle, and a spheroidizing agent such as Mg and an inoculant such as Mn and Cu are used. To adjust the chemical composition.
In step S65, the product is transferred to a hot water ladle for pouring hot water into the sand mold 104, and is moved to a predetermined position on the production line to be poured. Information (4) such as inoculants of the ladle 31 is recorded in the database DB (external record) together with the ladle number.

In step S7, the molten metal having the adjusted components is poured into the sand mold 104. Further, the manufacturing record information (pot number, pouring start time, pouring end time, processing amount, component information) of the pan 31 is managed as manufacturing data. In addition, sand mold information and molten metal information for manufacturing data management are linked to the manufacturing number and identification number. Then, the identification symbol change process is performed according to the progress of the production plan.

FIG. 17 is a flowchart showing the identification symbol change process of the first embodiment. The identification symbol change process is carried out in the flow of the manufacturing data management method. In order to help understanding the change of the identification symbol, the steps that overlap with other steps are also described.
In step S71, the identification symbol is attached to the main mold. This process is the process performed in step S4 described above.
In step S72, a sand mold is formed. This process is the process performed in step S5 described above.
In step S73, hot water is poured from the hot water ladle. This process is the process performed in step S6 described above.
In step S74, it is determined whether or not the poured sand mold number S1 has reached the production plan number S2, and if not, the process returns to step S72 and the sand mold molding is repeated. On the other hand, when it is reached, the process proceeds to step S75.
In step S75, it is determined whether or not the identification symbol has been changed by one digit or more, and if the identification symbol has been changed by one digit or more, all the identification symbols need to be replaced, so that this control flow is terminated. On the other hand, if the change is not made by one digit or more, it is determined that there is room for change, and the process proceeds to step S76.
In step S76, a part of the identification symbol is changed. Partially means, in addition to cutting the dots of the second marking material 2, the replacement of a part of the first marking material 1 representing a date or the like.
In step S77, the identification symbol is inspected. Specifically, it is confirmed by image processing of the camera whether or not the identification symbol is properly cut or replaced as instructed, or visually confirmed by the operator. If it is inappropriate, the process proceeds to step S78, and the identification symbol is replaced so as to be an identification symbol according to the production plan, or the dots are appropriately cut to obtain an appropriate identification symbol. When an appropriate identification symbol is obtained, the process returns to step S72 and molding of the sand mold is started.

That is, production is performed with the same identification symbol until the planned number of production corresponding to the identification symbol and the quantity molded with the sand mold 104 match. Then, after the production corresponding to the product identification code is completed, the identification code is changed. For example, when the ladle 31 is changed, a command for cutting the dots of the second marking material 2 and changing the number of dots is output to the robot computer RC. When all the dots of the second marking material 2 are cut, the second marking material 2 is replaced. In addition, when a part of the first marking material 1 representing information such as a date in the identification symbol is also changed, the first marking material 1 that needs to be changed among the identification symbols is partially replaced. .. At this time, production record information such as an identification symbol (product number and identification number), a production date, a ladle number, and a production start time is sent to the production control computer MC.

Here, for the material component information, a test piece that can be analyzed when each ladle is poured into the sand mold 104 is simultaneously produced, and the material component is analyzed using this test piece. As the analysis method, ICP emission spectroscopic analysis, fluorescent X-ray diffraction and the like are performed. In ICP emission spectroscopy, an analytical sample is dissolved in an aqueous acid solution, the sample solution is atomized, and high frequency inductive plasma is generated with argon gas. Then, a sample solution is issued in the sample solution, and the quantitative chemical composition is specified from the wavelength peculiar to each element and the emission intensity thereof. In fluorescent X-ray analysis, the analysis sample is irradiated with X-rays, and the quantitative chemical composition is identified from the fluorescent X-rays peculiar to each element emitted.

This analysis result and the ladle number are sent to the production control computer MC as production record information (4), and the identification symbol (product number and identification number), the ladle number, the component information, the working time, etc. are associated with each other. At this time, if necessary, a worker directly involved in each process selects a registered worker and manages it as production record information in the same manner.

In step S8, a drum cooler step is performed. Specifically, the casting (product) and the sand mold 104 are cooled, and after the cooling is completed, the casting and the sand mold 104 are put into the rotary drum, and water is injected while rotating the rotary drum to remove the sand. At this time, as the sand removal condition information (5), the treatment start time, water injection time, water injection amount, and rotation speed are managed as manufacturing data. Then, the sand removal condition information is associated with the product number and the identification number in the manufacturing data management.

In step S9, a weir folding step is performed. Specifically, excess molding parts such as gates and runners are removed. At this time, the processing start time, the gate removal pressure, the press pressure, and the like are managed as manufacturing data as the surplus molding portion removal condition information (6). Then, the surplus molding part removal condition information is associated with the product number and the identification number in the manufacturing data management.

In step S10, a blasting step is performed. Specifically, the sand removal finishing treatment and the finishing treatment of the casting (product) are carried out. At this time, as the blast condition information (7), the processing start time, processing time, current value, etc. are managed as manufacturing data. Then, the blast condition information is associated with the product number and the identification number in the manufacturing data management.

When different ladle 31s are confused in the production process such as the dam folding process and the blasting process, the condition information of each process is keyed to the change of the conditions based on the start time and the processing time for each ladle. Collect as information. Then, by extracting as two parameters such as a standard deviation as the average value and the amount of variation of the fluctuating conditions, it can be managed as process information for each ladle.

In step S11, an inspection step is performed. Specifically, the appearance inspection, strength inspection, hardness inspection, nest and hot water boundary inspection of the casting (product) are performed, and for a product satisfying the quality standard (hereinafter referred to as a non-defective product), the process proceeds to step S112. For a product that does not satisfy the quality standard (hereinafter referred to as a defective product), the process proceeds to step S110. Then, these inspection result information (8) are managed as manufacturing data. Then, the inspection result information is associated with the product number and the identification number in the manufacturing data management.

In step S110, a reworking step for defective products is carried out. The reworking step is mainly related to the appearance processing as in the blasting step of step S10, but other reworking may be performed and is not particularly limited.

In step S111, the reprocessed product obtained by reprocessing the defective product is re-inspected, and if it becomes a non-defective product, the process proceeds to step S112, and if it is a defective product, it is processed as a raw material in the molten metal treatment of step S6.

In step S112, a sorting step is performed. Specifically, a sorting step of transferring the products judged to be non-defective in step S11 to the shipping pallet process 113 is carried out, and a re-sorting step of separately transferring the products flowing from the re-inspection step S111 to the shipping pallet process 113. To carry out.

In the shipping pallet process S113, the product having the identification symbol is housed in the product pallet P to which the identification code is attached. At this time, as a general rule, the product manufactured in the same ladle 31 is housed in the product pallet P, and the identification symbol and the identification code are associated with each other. Further, as shown in step S112 of FIG. 14, when the number of products (laddle lot a) manufactured in the same ladle 31 exceeds the number that can be accommodated in the product pallet P1 (for example, 2), the following The product (ladle lot a) is stored in the product pallet P2. When the number of products in the ladle lot a is less than the number that can be accommodated in the product pallet P2, the products produced in the next ladle lot b are accommodated. At this time, the identification code of the product pallet P and the identification symbol of the product are acquired, and both data are linked and recorded in the database (external record).

FIG. 22 is a diagram showing a relationship in which the identification code of the product pallet of Example 1 and the identification symbol of the product are associated with each other. The identification code (81) is obtained in the sorting process, the product pallet identification code is obtained (82) in the shipping pallet process, and in the case of only products in these same ladle lots, the product pallet P identification code and the product The identification code and the number of shipments are linked (82: corresponding to the identification information acquisition process). When products from different ladle lots are housed together, a plurality of identification symbols and the number of shipments of each are associated with the identification code of one product pallet P (82).

Further, in the sorting step, a re-sorting step of accommodating the reprocessed product which has been determined to be a non-defective product in the re-inspection step S111 and has flowed into the product pallet P is also carried out. Here, when re-sorting, the product pallet P having an identification code associated with the same identification symbol as the identification symbol of the reprocessed product is searched for and stored. As a result, by shifting to the reprocessing process, even products that are once off the production line can be collectively stored as products manufactured from the same ladle, and confusion at the time of shipment can be suppressed. In addition, if there is no product pallet P having an identification code associated with the same identification code as the identification code of the reprocessed product, or if there is no space that can be accommodated, the product manufactured from another ladle It is housed in the product pallet P associated with the identification symbol. At this time, since the identification code of the product pallet P is associated with the plurality of identification symbols and the number of shipments of each, it is possible to improve the storage efficiency while suppressing confusion at the time of shipment.

In step S12, the casting (product) is shipped and delivered. At this time, the shipping / delivery status of the casting (product) associated with the serial number and the identification number is managed as the shipping / delivery information (9) for inventory management.
In step S13, the quality information at the customer is managed as manufacturing data (10) for suppressing recall for the product corresponding to the product number and the identification number.

The molding data collected from each of the above steps is output to the production control computer MC and then stored in the database DB. Then, the quality factor effect analysis computer AMC performs the quality factor effect analysis based on the information stored in the database DB.
FIG. 20 is a flowchart showing the quality factor effect analysis process of the first embodiment.
In step S101, the product number and the identification number are encoded.
In step S102, the identification number is associated with various production process information.
In step S103, the identification number and the quality inspection result are associated with each other.
In step S104, the phenomena of non-defective products and defective products are classified.
In step S105, the correlation analysis between the production process information (control factor) that affects the quality and the inspection result is performed.
In step S106, the production process information (control factor) that realizes quality improvement is reviewed and determined.

FIG. 21 is a flowchart showing an analysis process when a product having a problem in strength (hereinafter referred to as a strength NG product) appears in the quality factor effect analysis process of Example 1.
In step S201, the associative information of the strength NG product is extracted based on the information of (1) to (7) collected in the production process and the inspection result information (8).
In step S202, the strength is NG by analysis such as data mining from the past database information of the products (hereinafter referred to as strength OK products) and the strength NG products (1) to (8) in which the strength is not a problem. Extract the pattern leading to the product.
In step S203, the database analysis result is compared with the phenomenon of the strength NG product and the information of the production process. For example, one of the causes is to understand that the amount of Mg added to the ladle in the production process information (4) is small and the pouring time is long.
In step S204, the production process necessary for quality improvement and the condition extraction thereof are performed. For example, for the cause identified above, measures are taken to increase the amount of Mg added as a component of the ladle in the production process information (4) and shorten the pouring time.
In step S205, the production process information (control factor) that realizes stable strength is reviewed, and necessary measures are applied to the necessary places.

[Effect of Example 1]
Hereinafter, in Example 1, the following effects can be obtained.

(1) This is a production control method for a cast product, which is produced by inoculating the molten metal distributed from the melting furnace 30 to the ladle 31 and then sequentially pouring the molten metal into the conveyed sand mold 104 (mold).
A sand mold manufacturing process (molding process) for forming a sand mold 104 having an identification symbol for identifying the ladle 31 on the surface forming the cavity of the casting product, and
A sorting process in which the cast product taken out from the sand mold 104 is placed in a predetermined product pallet P based on the identification symbol transferred to the cast product satisfying the quality standard in light of the quality standard.
The identification information acquisition process for acquiring the identification code data of the cast products sorted by associating with the identification code given to the product pallet P, and the identification information acquisition process.
Have,
A reprocessing process (finishing process) for processing castings that do not meet quality standards,
When the processed casting is compared with the quality standard and the quality standard is satisfied, the sorting process (resorting process) in which the corresponding product pallet P is specified and stored based on the information acquired in the identification information acquisition process from the identification symbol of the casting. )When,
Have.
Therefore, even a non-defective product reprocessed by reprocessing a defective product can be stored in the same product pallet P as the non-defective product manufactured by the molten metal of the same ladle 31, and confusion at the time of shipment can be suppressed.

(2) The identification symbol is composed of a plurality of letters formed in a convex shape for specifying a casting product and a special convex symbol displayed by a plurality of protrusions.
That is, many character string patterns can be constructed by constructing a character string from any combination of characters and special characters. Therefore, even when a large number of products of a plurality of types are manufactured, a large number of types of character strings can be created by combining a small number of characters and special characters, which facilitates identification.

(3) The special symbol is displayed as a plurality of dot groups. Therefore, the pattern of the dot symbol can be changed by cutting the dots or the like, and the identification symbol can be changed quickly without affecting the tact time of casting.

(4) The identification symbol is changed to a different identification symbol by cutting off an arbitrary position among the plurality of dots of the special symbol for each number of pouring water into the mold by the ladle 31.
That is, regarding the marking material for subdividing and managing the identification symbol, some of the identification symbols that are changed infrequently, such as the product code and the date, are changed to multiple characters that are easy to recognize, and are changed multiple times per day. Codes that need to be changed frequently, such as, were cast as a special character composition. As a result, even for products that are cast in sand molds, such as ductile cast products, it is possible to assign subdivided identification symbols according to frequently changing casting conditions, which makes it possible to achieve high traceability. can.

(5) The identification symbol is written on a marking material in which a plurality of characters and special symbols are listed, and the marking material is affixed to the main mold for molding the mold. Therefore, the identification symbol can be easily cast on the cast product.

(6) The identification symbol is changed for each number of hot water poured into the mold by one ladle 31.
That is, the pattern of the dot symbol can be changed by cutting the dots or the like, and the identification symbol can be changed quickly without affecting the tact time of casting. Then, by managing the identification code in association with the manufacturing data, the traceability of the product can be improved.

(7) At the time of pouring, the present invention includes step S7 (pot information acquisition step) of acquiring data for specifying the pouring pot 31 associated with the poured mold. Therefore, the information for each ladle 31 can be associated with the identification symbol.

(8) Prior to the sorting process, it was decided to perform a weir folding process and a blasting process (processing to remove unnecessary parts of the cast product). Therefore, by reducing the occurrence of defective products and reducing the ratio of non-defective reprocessed products, it is possible to improve the sorting rate of the ladle to the product pallet P.

[Example 2]
Next, Example 2 will be described. Since the basic configuration is the same as that of the first embodiment, only the differences will be described. FIG. 23 is a flowchart showing the manufacturing data management method of the second embodiment. In Example 1, the flow of manufacturing one kind of product has been described. On the other hand, the second embodiment is a production control method for a multi-product cast product in which different types of products are produced from the same ladle. Steps S1 to S9 are the same as in the first embodiment, and the products A and B are manufactured by pouring hot water into the sand molds corresponding to the products A and B. Then, the sorting process for the product A and the product B is carried out, and the products A and B move to the finishing line set according to each product. After being sorted into the finishing line of product A and the finishing line of product B, the blasting process, the inspection process, the reprocessing process, and the re-inspection process for each of the products A and B are the same as in steps S10 and subsequent steps of Example 1. , Sorting process, shipping pallet process are carried out. Further, if the defective product is reprocessed and it is determined to be a non-defective product in the re-inspection process, the product is transferred to each finishing line and stored in the product pallet P containing the same product as in Example 1. ..

In Example 2, the following effects can be obtained.
(9) This is a production control method for a wide variety of castings, which is manufactured by mixing molds for many types of castings with the same casting equipment.
A sand mold manufacturing process (molding process) in which a mold with an identification symbol for identifying the ladle 31 is formed on the surface forming the cavity of the casting product, and
The finishing process of processing the casting taken out from the sand mold 104,
An inspection process that evaluates processed castings against quality standards,
Based on the identification code of the casting that satisfies the quality standard, the sorting process to put it in the predetermined product pallet P and
The identification information acquisition process for acquiring the identification code data of the cast products sorted by associating with the identification code given to the product pallet P, and the identification information acquisition process.
Have,
A refinishing process that reprocesses castings that do not meet quality standards in the inspection process,
A re-inspection process that evaluates reprocessed castings against quality standards,
When the reprocessed cast product satisfies the quality standard, the re-sorting process in which the corresponding product pallet P is specified and stored based on the information acquired in the identification information acquisition process from the identification symbol of the cast product, and the re-sorting process.
Have.
Therefore, a specific casting is stored in the same product pallet P, and the specific casting is managed by associating the identification symbol with the manufacturing data, so that it is easy to manage including defective reprocessed good products. can.

(10) The identification symbol is composed of a plurality of characters formed in a convex shape for specifying a casting product and a special convex symbol displayed in a plurality of dot groups.
That is, many character string patterns can be constructed by constructing a character string from any combination of characters and special characters. Therefore, even when a large number of products of a plurality of types are manufactured, a large number of types of character strings can be created by combining a small number of characters and special characters, which facilitates identification.

(11) The dot is changed to a different recognition symbol by cutting off an arbitrary position for each number of molds formed according to the number of hot waters that can be poured into the ladle 31. This makes it possible to manage casting process information for each product while quickly changing the identification symbol without affecting the casting tact time.

(12) In the re-sorting process, if there is no product pallet P corresponding to the cast product that satisfies the reprocessed quality standard, it is placed in another product pallet P that houses the cast products of different molten metal lots of the same product. In the identification information acquisition process, the identification code of the stored product pallet and the data of the identification symbol of the reprocessed casting product are associated and acquired.
That is, even if the reprocessed cast product is stored in a different product pallet P, the history of the product pallet P and the cast product remains, so that confusion at the time of shipment can be suppressed.

(13) In the sorting process, if the number of pallets that can be accommodated in the product pallet corresponding to the cast product of the predetermined ladle is less than the number that can be accommodated in the product pallet, the next ladle is used until the number of pallets that can be accommodated is reached. Accommodates castings,
In the identification information acquisition process, the identification code of the stored product pallet and the data of the identification code of the casting of the next ladle are linked and acquired.
That is, even if there are not enough castings to be stored, another lot of castings is stored in the product pallet P, and the history of the product pallet P and the casting remains. Can be improved.

(14) The inspection step moves to a finishing line provided according to the type based on the identification symbol transferred to the separated casting. Therefore, the finishing process can be dispersed according to the product, and the defective product can be quickly reprocessed.

(15) It has a step S7 (inoculation information acquisition step) of acquiring the data of the inoculation process carried out in the ladle 31 and associating it with the identification symbol. Therefore, the information for each ladle 31 can be associated with the identification symbol.

(16) The present invention includes step S3 (sand mold information acquisition step) of acquiring the sand mold data used for the mold and associating it with the identification symbol. Therefore, the information for each ladle 31 can be associated with the identification symbol.

(17) In the sand mold manufacturing process (molding step), the core is placed in the cavity, and in step S3, the core manufacturing data is acquired. Therefore, the manufacturing information of the core can be easily associated with the identification symbol.

[Example 3]
FIG. 24 is an example of a product having a marking material area in another embodiment, and FIG. 25 is an example of taking a large number of products having a marking material area in another embodiment. For example, when casting the brake caliper 600 of the vehicle brake device, as shown in FIG. 25, a plurality of brake calipers are cast from one sand mold, and then the molds are disassembled. At this stage, the runner and the gate remain in addition to the part of the brake caliper 600. From this state, a weir folding process and a blasting process are performed to obtain one brake caliper 600. At this time, as shown in FIG. 24, a partially recessed marking material area 601 is provided on the side surface of the brake caliper, and the identification symbol 600a formed of the marking material is formed therein. As a result, it is possible to suppress the deformation of the dot characters due to the collision of the products with each other in the process of removing the mold and removing the sand.

1 1st marking material 2 2nd marking material 2a Base part 2b Dot 2c Tip 10 Main mold 10a Marking material area 10d Lower main mold 10u Upper main mold 11 Hot sprue 30 Ladle 31 Ladle 32 Adjustment device 102 Lower sand mold 103 Upper sand mold 104 Sand mold 105 Cutting hand 600 Brake caliper 601 Marking material area
AMC quality factor effect analysis computer
DB database
MC production control computer
RB robot
RC robot computer

Claims (11)

It is a production control method for castings that is manufactured by inoculating the molten metal distributed from the melting furnace to the ladle and then pouring it into the conveyed molds in sequence.
A molding process of forming a mold with an identification symbol for identifying a ladle on the surface forming the cavity of the casting, and
A sorting process in which the casting taken out from the mold is compared with the quality standard and placed in a predetermined product pallet based on the identification symbol transferred to the casting satisfying the quality standard.
The identification information acquisition process for acquiring the data of the identification code of the cast product sorted by associating it with the identification code attached to the product pallet, and the identification information acquisition process.
Have,
The finishing process for processing castings that do not meet the above quality standards,
When the processed casting is compared with the quality standard and the quality standard is satisfied, the re-sorting process for identifying and storing the corresponding product pallet based on the information acquired in the identification information acquisition process from the identification symbol of the casting, and the re-sorting process.
Production control method for castings with. In the method for controlling the production of a cast product according to claim 1,
The identification symbol is a method for controlling production of a casting, characterized in that the identification symbol is composed of a plurality of characters formed in a convex shape for specifying a casting product and a special convex symbol displayed by a plurality of protrusions. .. In the method for controlling the production of a cast product according to claim 2.
The special symbol is a production control method for a casting, characterized in that it is displayed by a plurality of dot groups. In the method for controlling the production of a cast product according to claim 3.
The identification symbol is a production control of a casting product, characterized in that an arbitrary position is cut off from a plurality of dots of the special symbol and changed to a different identification symbol for each number of times the hot water is poured into the mold by the ladle. Method. In the method for controlling the production of a cast product according to claim 2.
The identification symbol is written on a marking material in which the plurality of characters and the special symbol are listed.
The marking material is a method for controlling the production of a cast product, characterized in that the marking material is attached to a main mold for molding a mold. In the method for controlling the production of a cast product according to claim 1,
The identification symbol is a method for controlling the production of a casting, characterized in that the symbol is changed for each number of pouring water into a mold by one ladle. It is a production control method for a wide variety of castings that is manufactured by mixing molds for many types of castings with the same casting equipment.
A molding process of forming a mold with an identification symbol for identifying a ladle on the surface forming the cavity of the casting, and
The finishing process of processing the casting taken out of the mold,
An inspection process that evaluates processed castings against quality standards,
Based on the identification code of the cast product that satisfies the quality standard, the sorting process of putting it in a predetermined product pallet and
The identification information acquisition process for acquiring the data of the identification code of the cast product sorted by associating with the identification code given to the product pallet, and the identification information acquisition process.
Have,
A refinishing process for reworking castings that do not meet quality standards in the inspection process,
A re-inspection process that evaluates the reprocessed castings against the above quality standards, and
When the reprocessed cast product satisfies the quality standard, a re-sorting process of identifying and storing the corresponding product pallet based on the information acquired in the identification information acquisition process from the identification symbol of the cast product, and a re-sorting process.
A production control method for a wide variety of cast products, which is characterized by having. The production control method for a high-mix cast product according to claim 7.
The identification symbol is a multi-product casting product characterized in that it is composed of a plurality of convex characters forming a convex shape for specifying a casting product and a special convex symbol displayed by a plurality of dot groups. Production control method. The production control method for a high-mix cast product according to claim 8.
The dot is a production control method for a high-mix cast product, characterized in that an arbitrary position is cut off for each number of molds formed according to the number of pouring pots that can be poured, and the dots are changed to different recognition symbols. The production control method for a high-mix cast product according to claim 7.
In the re-sorting process, if there is no product pallet corresponding to the cast product that satisfies the reprocessed quality standard, it is stored in another product pallet that stores the cast products of different molten metal lots of the same product, and identification information is acquired. A production control method for a high-mix casting product, which comprises associating and acquiring the identification code of the contained product pallet and the data of the identification code of the reprocessed casting product in the process. The production control method for a high-mix cast product according to claim 10.
In the sorting step, if the number of products to be stored in the product pallet corresponding to the cast product of the predetermined ladle is less than the number of products that can be stored in the product pallet, the cast product of the next ladle is used until the number of products to be stored in the product pallet is reached. Contained and
A method for producing and controlling a wide variety of cast products, which comprises associating and acquiring the identification code of the stored product pallet and the data of the identification symbol of the casting of the next ladle in the identification information acquisition step.

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