US 6,779,583 B1 · Die casting process incorporating iterative process parameter adjustments · patentgrep

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Abstract

A die casting process uses information derived from analysis of a prior casting to modify the process producing a subsequent casting. An aluminum alloy casting is manufactured at a first location. During the manufacture thereof, plural physical parameters are measured and recorded in an entry in memory. Further during the manufacture thereof, the casting is marked with a unique identifier which is stored, with the plural physical parameters, in the entry. The castings are then shipped to a second location, remotely located relative to the first location, for chrome plating. The chrome plated castings are examined for defects and, using the unique identifier on the casting, the casting is associated with the entry containing the physical parameters under which it was manufactured. The physical parameters may then be adjusted so that the subsequent castings are manufactured under conditions less likely to produce defects.

Claims23

Dependent claims

A method for manufacturing castings, comprising:

selecting a first set of conditions for the manufacture of castings;
manufacturing a first series of castings under said first selected set of conditions;
measuring the level of each one of said first selected set of conditions during the manufacture of said first series of castings;
marking each one of said first series of castings with a unique identifier;
identifying defects in said first series of castings;
selecting a second set of conditions for the manufacture of castings, said second set of conditions determined by modifying said first selected set of conditions based upon said identified defects in said first series of castings;
and
manufacturing a second series of castings under said second set of conditions;
wherein selecting a first set of conditions for the manufacture of castings further comprises:
identifying a set of conditions which affect the manufacture of castings;
performing a first set of Taguchi Design Of Experiments (“DOEs”) to determine which, of said identified set of conditions, exert the most influence on the quality of said castings to be manufactured;
wherein said selected set of conditions is comprised of said conditions determined as exerting the most influence on the quality of said castings to be manufactured;
and
wherein selecting a second set of conditions for the manufacture of castings further comprises:
associating a first one of said identified defects in said first series of casting with the level of each one of said first selected set of conditions during manufacture of a casting having said first one of said identified defects;
based upon said association of said identified defect with the level of each one of said first selected set of conditions during manufacture of said casting having said identified defect, identifying one or more of said first selected set of conditions in need of modification;
and
modifying the level of said identified one or more of said first selected set of conditions.

15 more elements

A method for manufacturing castings, comprising:

selecting a set of conditions for the manufacture of castings;
manufacturing a first series of castings under said selected set of conditions, said manufacturing of said first series of castings under said selected set of conditions further comprising:
measuring the level of each one of said selected set of conditions during the manufacture of said first series of castings;
and
marking each one of said first series of castings with a unique identifier;
identifying defects in said first series of castings;
modifying said selected set of conditions based upon said identified defects in said first series of castings, said modifying of said selected set of conditions based upon said identified defects in said first series of castings further comprising:
associating a first one of said identified defects in said first series of castings with the level of each one of said selected set of conditions during manufacture of a casting having said first one of said identified defects;
based upon said association of said identified defect with the level of said selected set of conditions during manufacture of said casting having said identified defect, identifying one of said selected set of conditions in need of modification;
and
modifying the level of said identified ones of said selected set of conditions;
and
manufacturing a second series of castings under said modified set of conditions;
wherein said castings are formed of either aluminum or an aluminum alloy;
and
wherein said defects are identified during an inspection of said aluminum or aluminum alloy castings after said aluminum or aluminum alloy castings are chrome plated.

13 more elements

A method for manufacturing castings, comprising:

selecting a set of physical parameters;
selecting a first level for each one of said selected set of physical parameters;
manufacturing a first series of castings with each one of said selected set of physical parameters set at said first selected level therefor;
for each one of said first series of castings:
measuring the actual level of each one of said selected set of physical parameters during the manufacture of said casting;
marking said casting with a unique identifier;
associating said measured level of each one of said selected set of conditions during the manufacture of said casting with said unique identifier for said casting;
examining said casting for defects;
and
if one or more defects are identified on said casting, using said unique identifier marked on said defective casting to associate said defective casting with said measured level of each one of said selected set of physical parameters during the manufacture of said defective casting;
selecting a second level for each one of said selected set of physical parameters, said second level for each one of said selected set of physical parameters determined by modifying said first selected set of conditions based upon said identified defects in said first series of castings;
and
manufacturing a second series of castings with said selected set of physical parameters set at said second selected level therefor;
wherein selecting a set of physical parameters further comprises:
identifying a set of parameters which affect the manufacture of castings;
and
performing a first set of Taguchi Design Of Experiments (“DOEs”) to determine which, of said identified set of parameters, exert the most influence on the quality of said castings to be manufactured;
wherein said selected set of physical parameters is comprised of said parameters determined as exerting the most influence on the quality of said castings to be manufactured.

15 more elements

A method for manufacturing castings, comprising:

selecting a set of physical parameters;
selecting a first level for each one of said selected set of physical parameters;
manufacturing a first series of castings with each one of said selected set of physical parameters set at said first selected level therefor;
for each one of said first series of castings:
measuring the actual level of each one of said selected set of physical parameters during the manufacture of said casting;
marking said casting with a unique identifier;
associating said measured level of each one of said selected set of conditions during the manufacture of said casting with said unique identifier for said casting;
examining said casting for defects;
and
if one or more defects are identified on said casting, using said unique identifier marked on said defective casting to associate said defective casting with said measured level of each one of said selected set of physical parameters during the manufacture of said defective casting;
selecting a second level for each one of said selected set of physical parameters, said second level for each one of said selected set of physical parameters determined by modifying said first selected set of conditions based upon said identified defects in said first series of castings;
and
manufacturing a second series of castings with said selected set of physical parameters set at said second selected level therefor;
wherein selecting a set of physical parameters further comprises:
identifying a set of parameters which affect the manufacture of castings;
and
performing a first set of Taguchi Design Of Experiments (“DOEs”) to determine which, of said identified set of parameters, exert the most influence on the quality of said castings to be manufactured;
wherein said selected set of physical parameters is comprised of said parameters determined as exerting the most influence on the quality of said casting to be manufactured;
and
wherein said defects are identified during an inspection of said aluminum or aluminum alloy castings after said aluminum or aluminum alloy castings are plated.

17 more elements

A method for manufacturing castings, comprising:

selecting a set of physical parameters;
selecting a first level for each one of said selected set of physical parameters;
manufacturing a first series of castings with each one of said selected set of physical parameters set at said first selected level therefor;
for each one of said first series of castings:
measuring the actual level of each one of said selected set of physical parameters during the manufacture of said casting;
marking said casting with a unique identifier;
associating said measured level of each one of said selected set of conditions during the manufacture of said casting with said unique identifier for said casting;
examining said casting for defects;
and
if one or more defects are identified on said casting, using said unique identifier marked on said defective casting to associate said defective casting with said measured level of each one of said selected set of physical parameters during the manufacture of said defective casting;
selecting a second level for each one of said selected set of physical parameters, said second level for each one of said selected set of physical parameters determined by modifying said first selected set of conditions based upon said identified defects in said first series of castings;
and
manufacturing a second series of castings with said selected set of physical parameters set at said second selected level therefore;
wherein selecting a set of physical parameters further comprises:
identifying a set of parameters which affect the manufacture of castings;
and
performing a first set of Taguchi Design Of Experiments (“DOEs”) to determine which, of said identified set of parameters, exert the most influence on the quality of said castings to be manufactured;
wherein said selected set of physical parameters is comprised of said parameters determined as exerting the most influence on the quality of said castings to be manufactured;
and
wherein said defects are identified during an inspection of said aluminum or aluminum alloy castings after said aluminum or aluminum alloy castings are chrome plated.

17 more elements

Dependencies are inferred from the claim text.

Facts

Application: 10/208,106Filed 30 Jul 2002 · us provisional application
Priority: 21 Jun 2002
Granted: 24 Aug 2004
Term ends: Not estimatedThe source records don’t support an estimate.

Classification4 codes

B22D 46/00
Controlling, supervising, not restricted to casting covered by a single main group
B22D 17/2245
Dies ; Die plates; Die supports; Cooling equipment for dies; Accessories for loosening and ejecting castings from dies: having walls provided with…
B22D 17/32
Accessories: Details: controlling equipment
B22D
Casting of metals

Family

Application60/390,779Us provisional application · filed 21 Jun 2002
US 6,779,583 B1This patent

From the US filing history. Foreign family members aren’t listed.

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