How to Detect Stuck Bullets in Rotating Lead Casting Molds Using Sensors?

The discussion addresses detecting stuck bullets in rotating lead casting molds that pour molten lead into multiple caliber-specific molds (9mm, 10mm, .45). The molds rotate, open, and drop bullets, but sometimes bullets remain stuck, causing molten lead spillage and operational issues. Proposed solutions include using optical or mechanical sensors positioned near the mold exit to detect the presence or absence of bullets by reflection or mechanical activation. If a bullet is detected as stuck, the machine can pause, attempt to dislodge the bullet via a mechanical actuator (e.g., a weighted linear actuator), and if unsuccessful, stop and alert the operator. Alternative detection methods suggested include capacitive sensors, fiber optic sensors rated for high temperatures, and weight-based detection systems. Preventative measures focus on reducing mold burring and sticking by applying graphite powder as a dry lubricant inside molds, which also improves bullet performance. However, caution is advised against liquid coatings due to buildup and steam explosion risks. Mold maintenance through careful cleaning and professional polishing is recommended to avoid burs that cause sticking. Brands mentioned for sensors include Keyence and Moeller Electric, with AutomationDirect cited as a supplier of fiber optic sensors. The discussion emphasizes combining sensor detection with mechanical clearing and preventive lubrication to ensure reliable mold emptying and casting quality.
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