Die casting process incorporating computerized pattern recognition techniques
View Patent ↗A die casting process using pattern recognition techniques to identify those die castings manufactured under conditions likely to produce a die casting which would subsequently prove unacceptable for use. By promptly identifying such die castings, they may be discarded before being shipped to a remote facility for further processing. As a result, the rejection rate of die castings at the remote facility may be reduced and the raw materials used to form the discarded die castings may be more readily recycled.
1. A method for identification of defects in castings created by die-casting manufacturing, comprising:
manufacturing a plurality of castings, each having a serialized unique identifier thereon;
inspecting each casting in approximate proximity to the manufacturing of such casting to detect defects; and
noting a description of each detected defect in a defect record associated with the corresponding casting within a database as inspected;
wherein the defect record for each casting further comprises the corresponding unique identifier.
2. The method of claim 1 , wherein inspecting each casting in approximate proximity to the manufacturing of such casting to detect defects comprises physically testing each manufactured casting for defects.
3. The method of claim 1 wherein manufacturing castings further comprises:
producing a first casting using a die; and
producing a second casting using the die without reworking the die subsequent to producing the first casting;
wherein the first casting has a first serialized unique identifier, and the second casting has a second serialized unique identifier different from the first serialized unique identifier.
4. The method of claim 3 further comprising:
marking the first serialized unique identifier on the first casting; and
marking the second serialized unique identifier on the second casting.
5. The method of claim 3 , wherein the first and second unique identifiers are stamped into the corresponding casting subsequent to ejection of the casting from the die.
6. A method as in claim 1 , wherein noting a description of each detected defect comprises recording a location and type of each defect detected for each casting, and occurs approximately in proximity to the detection of each defect.
7. A method as in claim 6 , further comprising:
sensing process parameters during the manufacture of each casting;
associating process parameters sensed for each casting with the corresponding unique identifier;
associating the process parameters for each casting with the corresponding defect record for each casting via the corresponding unique identifier;
analyzing the database in real-time by computer to detect one or more patterns;
identifying appropriate adjustments to one or more of the process parameters to address each detected defect pattern; and
modifying the die-casting manufacturing process in real-time according to the adjustments;
wherein associating the process parameters for each casting with the corresponding defect record occurs as each casting is inspected in approximate proximity to the die-casting manufacturing process.
8. A method as in claim 6 , wherein recording the location and type of each defect detected for each casting occurs via a user interface.
9. A method as in claim 1 , further comprising sensing process parameters during manufacture of each casting; and associating the process parameters for each casting with the corresponding defect record for each casting via the corresponding unique identifier.
10. A method as in claim 1 , further comprising:
analyzing the database to detect one or more defect patterns;
identifying appropriate adjustments to address each detected defect pattern; and
modifying the die-casting manufacturing process according to the adjustments.
11. A method as in claim 10 , wherein modifying the die-casting manufacturing process occurs in real-time and comprises adjusting one or more of the manufacturing conditions.
12. A method as in claim 10 , wherein analyzing the database and modifying the die-casting manufacturing process occur automatically via a computerized system.
13. A method as in claim 1 , further comprising performing a second inspection of each casting at a remote location, and adding a description of each additional detected defect in the defect record associated with the corresponding casting as inspected.
14. A method for identification of defects in castings created by die-casting manufacturing comprising:
manufacturing castings, each having a serialized unique identifier marked thereon;
inspecting each casting to detect defects;
recording a description of each detected defect in real-time in a defect record stored in a database;
wherein the defect record for each casting further comprises the corresponding unique identifier.
15. A method as in claim 14 , wherein recording a description of each detected defect in real-time comprises recording the location and type of each defect detected for each casting.
16. A method as in claim 15 , wherein recording the location and type of each defect detected for each casting occurs approximately in proximity to the detection of each defect.
17. A method as in claim 15 , wherein: inspecting each casting to detect defects occurs in proximity to the die-casting manufacturing process.
18. A method as in claim 15 wherein the location and type of each defect detected for each casting is recorded via a computerized user interface.
19. A method as in claim 18 , further comprising: sensing process parameters during the manufacture of each casting; associating process parameters sensed for each casting with the corresponding unique identifier; associating the unique identifier for each casting with the corresponding defect record for each casting; and associating the process parameters for each casting with the corresponding defect record for each casting via the corresponding unique identifier; wherein associating the process parameters for each casting with the corresponding defect record occurs as each casting is inspected in proximity to the die-casting manufacturing process, allowing for real-time adjustment of one or more of the process parameters of the die-casting manufacturing process based on detected defects.
20. A method as in claim 19 , further comprising: analyzing the database in real-time by computer to detect one or more defect patterns; identifying appropriate adjustments to one or more of the process parameters to address each detected defect pattern; and modifying the die-casting manufacturing process in real-time according to the adjustments.