CN101001963A

CN101001963A - Integrated metal processing facility

Info

Publication number: CN101001963A
Application number: CNA2005800246689A
Authority: CN
Inventors: S·P·克拉夫顿; P·M·克拉夫顿; 小J·L·刘易斯; I·弗伦奇
Original assignee: Consolidated Engineering Co Inc
Current assignee: Consolidated Engineering Co Inc
Priority date: 2004-06-02
Filing date: 2005-06-01
Publication date: 2007-07-18
Anticipated expiration: 2025-06-01
Also published as: JP5689403B2; JP5575365B2; WO2005121386A2; EP2319945A2; CN102000813B; JP2008501860A; JP2012040614A; MXPA06014028A; CN102000813A; EP1766100A2; JP2014073531A; EP1766100B1; KR20070024675A; WO2005121386A3; EP2319945A3; CN101001963B; EP2319945B1

Abstract

A integrated facility for forming and heat treating a metal casting is provided, the facility comprising: a pouring station for pouring a molten metal into a mold to form a casting; a process temperature control station downstream from said pouring station, said process temperature control station comprising a temperature sensing device in a heat treatment furnace; wherein said the temperature sensing device and said heat source are adapted to maintain the temperature of the casting at or above a process control temperature for the metal of the casting, and wherein upon receipt of a rejection signal from said temperature sensing device, said transfer mechanism removes the casting prior to entry into said furnace.

Description

Integrated metal processing facility

Background technology

Traditionally, in the traditional method that forms metal founding, for example have the metal die of inner chamber or the mold of sand mo(u)ld and be full of molten metal, described inner chamber portion has within it defined the external structure of wishing foundry goods.The core of qualification foundry goods internal structure holds or is placed in the mold, when molten metal solidifies around core, forms the interior details of foundry goods.After the molten metal of foundry goods solidified, foundry goods moved to usually to handle in the stove and carries out heat treating castings, removes the sand of core and/or mold, and other essential processing.The metal or metal alloy of heat treatment processes condition foundry goods is to obtain to be used for the desired physical properties of given application.

Usually, be transported to the process of heat treatment station from the cast station at foundry goods, if particularly allow foundry goods to place considerable time, foundry goods can be exposed in the external environment of casting or metal-working plant.As a result, foundry goods is easy to begin quick cooling from fusing or semi-molten temperature.Although need foundry goods cooling to a certain degree so that casting solidification, but casting temperature descends manyly more, the time that foundry goods remains under the casting process critical temperature (also be called technological temperature control) is long more, foundry goods is heated to required thermal treatment temp and foundry goods is heat-treated the needed time long more.For example, it has been found that for the metal of some type, foundry goods is reduced to each following minute of its technological temperature control, all the result that need realize wishing at least about four minutes extra heat treatment time.Therefore, even reduce under the technological temperature control of foundry goods metal shortly 10 minutes, also need extra heat treatment time about at least 40 minutes could obtain the physicals of hope.Therefore, for the thermal effectiveness that obtains to wish, these foundry goods needed thermal treatment 2-6 hour at least usually, and in some cases the time longer.This causes more energy to be used, and therefore causes higher thermal treatment cost.

Summary of the invention

In brief, the present invention generally include a kind of to the foundry goods that forms from metal or metal alloy pour into a mould, the integrated metal processing facility of shaping, thermal treatment and other processing.This integrated metal processing facility generally includes the cast station, and at this molten metal of aluminium or iron for example, or metal alloy is cast in mold or the mould, in for example nonvolatil metal mold, semi-permanent mold or the sand mold.Then, described mold moves to transfer position from the cast or the casting position of cast station, takes out from its mold or is transported on the heat-treatment production line at this foundry goods.Described transporting mechanism generally includes robots arm, lifting machine, overhead lift or elevator, push rod, travelling belt or similar transporting mechanism.Same mechanism also can be used for taking out foundry goods and foundry goods is sent on the heat-treatment production line from mold.From pouring into a mould station to transfer position and/or to the course of conveying of heat-treatment production line, the molten metal in the foundry goods can be cooled to be enough to form the degree of foundry goods this.

Described heat-treatment production line or thermal treatment unit generally include technological temperature control station and heat treatment station or heat treatment furnace, and described heat treatment furnace has one or more furnace chamber usually, and optionally, have the quench station that is usually located at the heat treatment station downstream.Described technological temperature control station is generally elongated chamber or passage, before foundry goods enters heat treatment station, receives foundry goods by described chamber or passage.Described chamber can comprise a series of thermals source, for example the heating unit of radiation heater, infrared, induction, convection current, conduction or other types.The wall and the top of described technological temperature control station also can comprise radiative material, and when foundry goods and/or mold moved through described chamber, these materials were usually towards described foundry goods and/or mold radiation or guiding heat.Alternatively, can use a series of thermals source, comprise radiant heater element, the thermal source of for example infrared and inductive heating element, convection current, conduction or other types is to direct into foundry goods or mold with heat at foundry goods or mold when the cast station is sent to heat treatment station.In addition, heating unit or thermal source directly can be installed on the transporting mechanism with heating foundry goods and/or sand mold.

When foundry goods and/or the mold that wherein has a foundry goods when passing technological temperature control station, the cooling of foundry goods is limited in technological temperature control or this is more than temperature.Technological temperature is controlled the normally required following temperature of solution heat treatment temperature of foundry goods metal, thereby make foundry goods be cooled to be enough to quantity or the degree that they are solidified, but under this temperature, foundry goods is elevated to its solution heat treatment temperature and subsequently the required time of heat treating castings is increased by index law.Foundry goods remains on its technological temperature control or this temperature is above till described foundry goods enters heat treatment station.

By stoping the foundry goods cooling and foundry goods being remained under the control of basic technology temperature or this temperature more than temperature of foundry goods metal, the needed time of heat treating castings can obviously reduce.Therefore, the work output of casting pouring station can increase, and like this, the whole processing and the heat treatment time of foundry goods can reduce.

Before entering heat treatment furnace, foundry goods passes through the inlet region.Casting temperature comes under observation to determine whether temperature reduces to pre-if below the predetermined outflow temperature.If casting temperature is equal to or less than outflow temperature, can use any proper device that foundry goods is taken away from heat-treatment production line.If foundry goods is acceptable, it just advances to and is used for heat treated heat treatment furnace.

Thermal treatment unit can include the structure that helps take away and/or reclaim core and/or mold.Thereafter, foundry goods can carry out additional processing, for example, and quenching, ageing treatment and/or other thermal treatment.

For a person skilled in the art, after the detailed description of having read below in conjunction with accompanying drawing, each purpose of the present invention, feature and advantage will be more obvious.

Description of drawings

Figure 1A is the synoptic diagram of the illustrative metal system of processing of all respects according to the present invention;

Figure 1B is the synoptic diagram of another illustrative metal system of processing of all respects according to the present invention, has shown collection and conveying from a plurality of cast stations to the foundry goods of thermal treatment unit;

Fig. 1 C is the synoptic diagram of another illustrative metal system of processing of all respects according to the present invention, wherein takes out refrigerant from mold;

Fig. 1 D is another example system of all respects according to the present invention, has shown the transporting mechanism that comprises heating unit;

Fig. 2 A is the illustrative processes temperature control station of all respects according to the present invention and the top plan view of heat treatment station;

Fig. 2 B is the lateral elevational view of control station of technological temperature shown in Fig. 2 A and heat treatment station;

Fig. 3 is the skeleton view of the exemplary batch processing system of all respects according to the present invention;

Fig. 4 A and 4B have shown according to the present invention the illustrative processes temperature control station of all respects, comprise source of conductive heating;

Fig. 5 A and 5B have shown according to the present invention another illustrative processes temperature control station of all respects, comprise direct heat source/impact (impingement) thermal source; And

Fig. 6 A and 6B have shown according to the present invention another illustrative processes temperature control station of all respects, comprise radiant heat source.

Embodiment

At length with reference to accompanying drawing, identical in the accompanying drawings Reference numeral is represented identical parts now.Figure 1A-3 schematically shows the method for integrated metal processing facility or system 5 and processing metal foundry goods.Metal casting technique is normally known in those skilled in the art, only briefly describes traditional casting technique for reference purpose below.Those skilled in the art will appreciate that the present invention can be used for the casting technique of any kind, comprise being used to be shaped the metal of aluminium, iron, steel and/or other types and the metal casting technique of metal alloy castings.Therefore, the present invention and not should not only limit to use with the metal or metal alloy of particular cast technology or particular type.

Shown in Figure 1A, molten metal or metal alloy M are poured in mould or the mold 10 to form foundry goods 12 at cast station or casting station 11 usually, for example, and cylinder head, engine body or similar foundry goods.The core of being made by the organic binder bond of sand and for example resol 13 holds or is placed in the mold 10, thereby produces cavity and/or foundry goods details or core print in the foundry goods.Alternatively, each mold can be nonvolatil mold or mould, and usually by metal, for example steel, cast iron or other materials known in the art are made.This mold can have clamshell type design, so that open and therefrom take out foundry goods.Still alternatively, described mold can be " precision sand " formula mold and/or " green sand mold ", these molds usually by with tackiness agent, for example resol or other binding agent blended sand material known in the art, for example silica sand or zircon sand are made, and are similar to sand core 13.Described mold also can comprise semi-permanent sand mold, and it has outside mold wall usually, and this wall is made by sand and matrix material, the metal of for example steel or the combination of two kinds of materials.

Should be understood that, term " mold " is generally used for referring to above-mentioned all types of mold hereinafter, comprise nonvolatil or metal die, semi-permanent and precision sand formula mold and other metal molds, but point out except the situation of particular type mold.It is to be further understood that, in following each embodiment, unless pointed out the mold and/or the thermal treatment process of particular type, otherwise the present invention can be used for the foundry goods that takes out from permanent mold is heat-treated, or the foundry goods that still remains in the sand mold heat-treated so that the thermal treatment of making up, and the destruction sand mold, reclaim sand.

Shown in Figure 1A, each mold 10 generally includes sidewall 14, upper wall or top 16, lower wall or bottom 17, and these walls have formed internal cavities 18 jointly, and molten metal is contained in this cavity and forms foundry goods 12.Cast gate 19 forms on the upper wall of each mold or top 16 usually and is communicated with internal cavities, is used for making the deposite metal by each mold and enter internal cavities 18 pouring into a mould station 11 places.Shown in Figure 1A-1C, cast station 11 generally includes cast packet or the kindred organization 21 that is used for molten metal M is poured into mold.Described cast station 11 also comprises travelling belt 22, for example disc type travelling belt, piston, calibration structure or similarly transporting mechanism, one or more mold is moved to point of delivery or position 24 from cast or casting position 23, wherein at the pouring position poured with molten metal in mold, foundry goods is taken out from its mold or the mold that will wherein have a foundry goods is transported on thermal treatment unit 26 or the heat-treatment production line from the cast station at transfer position.After molten metal had been poured in the mold, mold was sent to transfer position, and wherein, degree that metal is cooled to wish in the required mould of metal or temperature are to solidify the formation foundry goods.Foundry goods is heat-treated under the thermal treatment temp of hope subsequently.

It has been found that, when the foundry goods metal cools, it reaches herein temperature or the temperature range that is called " technological temperature control " or " technology critical temperature ", is lower than this temperature, and casting temperature is elevated to thermal treatment temp and heat-treats all significantly increases of required time.Those of ordinary skill in the art should be appreciated that size and dimension and many other factors of special metal that the technological temperature control that is used for the foundry goods handled by the present invention will be used according to foundry goods and/or metal alloy, foundry goods change.

On the one hand, technological temperature control is about 400 ℃ for some alloys or metal.On the other hand, technological temperature control can be approximately 400-600 ℃.On the other hand, technological temperature control can be approximately 600-800 ℃.On the other hand, technological temperature control can be approximately 800-1100 ℃.On the other hand, technological temperature is controlled for some alloys or metal, and for example iron can be approximately 1000-1300 ℃.In a particular instance, aluminium/copper alloy can have about 400-470 ℃ technological temperature control.In this example, technological temperature control is being used under the solution heat treatment temperature of most of copper alloys usually, and described solution heat treatment temperature typically is about 475-495 ℃.Although particular instance provided herein should be appreciated that size and dimension and many other factors of the special metal that uses according to foundry goods and/or metal alloy, foundry goods, technological temperature control can be any temperature.

When the metal of foundry goods was in the desired process temperature controlling range, foundry goods typically was cooled to be enough to solidifying like that according to hope.Yet, if allow the foundry goods metal cools to arrive it below technological temperature control, it has been found that, the foundry goods metal cooled off 1 minute below technological temperature control, foundry goods just needs additionally to heat about at least 4 minutes to reach the thermal treatment temp of hope, for example for aluminium/copper alloy being about 475-495 ℃, perhaps is about 510-570 ℃ for aluminum/magnesium alloy.Therefore, even foundry goods very short time of cooling under its technological temperature control, suitably and up hill and dale the needed time of the described foundry goods of thermal treatment also can be significantly elongated.In addition; will be appreciated that; in the batch processing system that shows in for example Figure 1B, 1C and 1D, wherein several foundry goods are handled in a collection of by heat treatment station, are used for the heat treatment time of foundry goods by the gross has minimum temperature usually based on this batch the required heat treatment time of foundry goods.Therefore, if one of processed foundry goods is cooled to be lower than it below technological temperature control in this batch, for example, continue about 10 minutes, usually need by the gross, for example the thermal treatment that additionally continues at least 40 minutes is to guarantee that all foundry goods are by suitably also thermal treatment up hill and dale.

Therefore, many aspects of the present invention relate to the (Figure 1A-Fig. 3) and handle the method for metal founding of integrated treatment facility or system 5.Described each system is designed to make (be positioned at its mold or separate with mold) foundry goods to move and/or be sent to heat treatment system or unit 26 from casting station 11, make the cooling of molten metal reach the technological temperature control of metal or this more than temperature simultaneously, but the thermal treatment temp of being less than or equal to its hope is to allow casting solidification.Therefore, many aspects of the present invention comprise that the system that is used to monitor casting temperature is to guarantee that foundry goods roughly remains on technological temperature control or this is more than temperature.For example, thermoelectricity occasionally other similar temperature sensing device or system can be placed on the described foundry goods, or contiguous this foundry goods places, or is placed on that successive monitors to provide roughly on from the casting station to the interval location of the foundry goods mobile route of heat treatment furnace.Alternatively, can adopt and be defined as the enough frequent timed interval and carry out periodicity and monitor.This device can link to each other with thermal source, and like this, temperature measuring or sensing device and thermal source can cooperate with the temperature with foundry goods and roughly remain on the technological temperature control of foundry goods metal or this is more than temperature.Should be clear, casting temperature can be measured by a specific position on foundry goods or in the foundry goods, perhaps can be by the medial temperature of measuring on the foundry goods or the temperature of a plurality of positions in the foundry goods calculates, any other mode that is perhaps required according to application-specific or that wish be measured.Therefore, for example, casting temperature can foundry goods on or a plurality of positions in foundry goods measure, and the minimum temperature of surveying, the top temperature of surveying, the medium temperature of surveying, the equal temperature of institute's lining or its any combination or variation may be calculated or be defined as to the total temperature value.

In addition, before entering heat treatment furnace, foundry goods can pass inlet or discharge area 110, and wherein the temperature of each foundry goods obtains monitoring to determine whether this foundry goods need has been cooled to too much energy temperature to be brought up to the degree of thermal treatment temp.The inlet region can be included in the technological temperature control station, perhaps can be the zone that separates, as pointing out usually in institute's drawings attached.Casting temperature can be by any suitable temperature sensing or measuring apparatus, and for example thermopair monitors to determine whether casting temperature has reached or drop to pre-if below the predetermined outflow temperature.On the one hand, the following temperature of the described predetermined outflow temperature technological temperature control that can be the foundry goods metal (for example, approximately 10-20 ℃).In yet another aspect, the temperature of (for example, about 10-20 ℃) below the thermal treatment temp that described predetermined outflow temperature can be heat treatment furnace or baking oven.If foundry goods has been cooled to be equal to or less than preset temperature, described Controlling System can send the discharge signal to transmitting or remove mechanism.In response to the detection of defect situation or signal, this foundry goods can be identified so that further assess or can take off from transmitting production line.Foundry goods can pass through any suitable mechanism or device, includes but not limited to that robots arm or other automatic gear are taken away, and perhaps described foundry goods can manually be taken away by the operator.

As mentioned above, should be clear, casting temperature can be measured by a specific position on foundry goods or in the foundry goods, perhaps can be by the medial temperature of measuring on the foundry goods or the temperature of a plurality of positions in the foundry goods calculates, any other mode that is perhaps required according to application-specific or that wish be measured.Therefore, for example, casting temperature can be measured a plurality of positions on foundry goods or in the foundry goods, and the minimum temperature of surveying, the top temperature of surveying, the medium temperature of surveying, the equal temperature of institute's lining or its any combination or variation may be calculated or be defined as to total value.

In Figure 1A and 2A-2B, first embodiment that shows integrated equipment 5 and be used for moving and/or processing the technology of foundry goods.Figure 1B and 3 also shows integrated equipment 5 and shaping and handles additional, the optional embodiment of the technology of foundry goods, and its medium casting is collected and processed by thermal treatment in batch processing formula device.Yet, those skilled in the art will appreciate that principle of the present invention goes for batch-type and the single continuous processing type equipment by described equipment of foundry goods equally.Therefore, following embodiment and not should not only limit to continuously or the processing units of batch-type.Fig. 1 C and 1D also show the optional embodiment that is used to carry out additional procedure of processing of the present invention, for example, remove refrigerant (Fig. 1 C) or foundry goods is transported to (Fig. 1 D) a plurality of heat treatment furnaces from foundry goods.In addition, those skilled in the art will appreciate that hereinafter that discuss and each structure embodiment illustrated in the accompanying drawings can be combined to form additional embodiment of the present invention.

In the embodiment shown in Figure 1A and the 2A-2B, carrying or pouring into a mould station 11 foundry goods 12 is taken out from its mold 10 by transporting mechanism 27.Shown in Fig. 2 A and 2B, delivery system or mechanism 27 generally include robots arm or lifting machine 28, yet it will be appreciated by those skilled in the art that, can use the various other systems and the device of mobile foundry goods and/or mold, for example overhead system lift or elevator, travelling belt, push rod or other materials similar carrying mechanisms.Shown in Figure 1A, 1B and 2A; robots arm 28 generally includes and is used to engage or joint or grip portion or the clamp 29 and the pedestal 31 of clamping mold or foundry goods; robots arm 28 is rotatably installed on the described pedestal, thereby can move shown in arrow 32 and 32 ' (Fig. 2 A) between point of delivery 24 of pouring into a mould station and heat-treatment production line.In addition, shown in Figure 1B, transporting mechanism can be used for from a plurality of cast stations 11 and 11 ' transfer molds and/or foundry goods, and described mold and/or foundry goods can be transported to a plurality of heat-treatment production lines or unit 26 (Fig. 1 C).

Usually, the mold that inside has a foundry goods moves to from cast station 11 and picks up or point of delivery 24 (Fig. 2 A), wherein transporting mechanism 27 picks up the mold that its inside accommodates foundry goods usually, or takes out foundry goods 12 and foundry goods 12 is transported to thermal treatment unit 26 from its mold.Like this, same mechanical arm or transporting mechanism can be used for taking out foundry goods from the cast station, and foundry goods is sent into thermal treatment unit.Usually, thermal source or heating unit 33 are adjacent to point of delivery 28 settings to provide heat to foundry goods.Described thermal source can comprise the heating unit or the thermal source of any kind usually, for example conduction, radiation, infrared, convection current and the direct thermal source of impingement.Shown in Fig. 2 A, can use a plurality of thermals source 33, it is positioned in from the course of conveying of cast station heat treated production line to foundry goods heat supply efficiently.

Usually, under the situation of permanent or metal die or mold, mold is opened at the point of delivery place, and takes out foundry goods by transporting mechanism, shown in Fig. 1 D.Then, described transporting mechanism is transported to foundry goods on one or more inlet travelling belt 34 (Figure 1B and 2A) of thermal treatment unit, production line or system 26 of integrated processing units 5.When mold is opened and take out foundry goods, along with foundry goods is transported to thermal treatment unit and makes foundry goods be exposed to the external environment of foundry, thermal source 33 (Fig. 2 A) directly applies heat to foundry goods, stop or otherwise control the cooling of foundry goods, thereby the technological temperature that can make foundry goods roughly remain on the foundry goods metal controls or this is more than temperature.

Processing for the foundry goods of making in semipermanent or the sand mold, usually remain in its mold at the heat treatment process medium casting, during this period, the thermal destruction of the binder material by keeping the mold sand destroys mold, and the whole mold that transporting mechanism 27 will wherein accommodate foundry goods is transported to inlet travelling belt 34 from point of delivery.Therefore, thermal source 33 will continue to apply heat to mold itself, and the heat that is applied is controlled so that the casting temperature in the mold maintains the technological temperature control of foundry goods metal roughly or this more than temperature, and can not cause mold excessively or too early to disintegrate.

Hereinafter, when mentioning conveying, heating, handle or other modes move or when processing foundry goods, unless otherwise noted, otherwise being appreciated that this argumentation comprises takes out and processing foundry goods itself and do not have their mold, and foundry goods remains on heat-treating process in the sand mold, the destruction of mold and core, and the recovery of sand, as U.S. Patent No. 5,294,994, No.5,565,046, No.5,738,162, No.6,217,317 and the U.S. Patent application No.09/665 that submits in 9 days September in 2000 of not concluding, the U.S. Patent application No.10/051 that submitted on January 18th, 354 and 2002, disclosed content in 666, its content is incorporated herein by reference in this integral body.

Shown in Figure 1A and 2A-2B, foundry goods begins by inlet travelling belt 34 (Fig. 2 A and 2B), or travelling belt 34 and 34 ' (Figure 1B) calibration or be sent to preset in chamber or technological temperature control workshop section or the module 36.Shown in Fig. 2 A and 2B, technological temperature control station or module generally include the inner chamber 37 of heating, its medium casting and/or its inside have the mold of foundry goods on chain conveyor, roller or similar transporting mechanism 38, pass through inner chamber 37 along its processing delivery pathways along heat-treatment production line.Foundry goods in the upstream or inlet end 39 enter chamber 37, and leave chamber 37, and directly send in the heat treatment furnace or station 42 of heat-treatment production line 26 usually by downstream or exit end 41.The entrance and

exit end

39 and 41 of technological temperature control station also can be opened, and maybe can comprise door or similar enclosed construction, shown in mark 43 among Fig. 2 B, thereby to help sealed chamber 37 to avoid too much calorific loss.Usually, foundry goods is directly sent into heat treatment station 42 from technological temperature control station 36, and wherein, thermal treatment and technological temperature control station link together, and have further avoided the potential calorific loss, if desired, also allow to divide equally heat.

Chamber 37 is radial pocket normally, comprises series installation thermal source 45 therein, and described thermal source is along the wall 46 of chamber and/or push up 47 and place.Usually, a plurality of thermals source 45 can be used, and one or more dissimilar thermals source or heating unit can be comprised, comprise radiant heating source, for example infrared, the electromagnetism or the induction energy, conduction, convection current or direct impingement heat source for example import gas flame the gaseous combustion pipe in the chamber.In addition, the sidewall of radiant chamber 37 and roof are made or are coated with high-temperature radiation material usually by high-temperature radiation material, for example metal, metallic film or analogous material, pottery or matrix material that can radiations heat energy.Described radiation coating forms non-adhering surfaces usually on sidewall and roof.When the sidewall of chamber and roof heating, sidewall and roof are easy to towards the foundry goods radiations heat energy, described surface can be heated to usually and be enough to waste gas and residual substance simultaneously, the temperature of the after-flames such as coal smoke that produce of the binding agent in sand mold and/or core burning is for example gathered on the sidewall of chamber and roof to avoid it.

Fig. 4 A-6B shows the multiple different embodiment of technological temperature control station.Fig. 4 A-4B illustrates the technological temperature control station 36 that comprises convection thermal source 45.Each source of conductive heating generally includes the nozzle or the gas blower 51 of one or more medium source that is connected in heating by conduit 52.In this respect, gas blower 51 arranges or is positioned around the roof 47 and sidewall 46 of chamber 37, thereby can make the medium of heating, and for example air or other gas and/or fluid import in the chamber, and import facing to being contained in its inner foundry goods and/or mold.Described convection blowers is tended to produce turbulent heating fluid stream usually around foundry goods, and is as shown in arrow 53, so that heat is applied on all sides of foundry goods and/or sand mold basically.As a result, casting temperature roughly remains on the technological temperature control of foundry goods metal or this is more than temperature.In addition, when foundry goods carries out in its sand mold under the situation of processing treatment, control the heat that applies in the station at technological temperature and be used for heated mold, its temperature is elevated to decomposes or temperature of combustion, under this temperature, binder material wherein takes fire, pyrolysis or otherwise separate.

On the other hand, gas blower or nozzle 52 are positioned at the front of the technological temperature control station of contiguous its inlet end, move under higher speed and/or temperature, so that stop the cooling of foundry goods and/or mold quickly.Towards the middle part and/or the end of chamber, for example the localized nozzle of outlet or the gas blower 52 of technological temperature control station can move under lower temperature and speed, thereby avoid sand mold to degrade fully, allow casting solidification simultaneously.

Alternatively, Fig. 5 A and 5B show technological temperature control station 36 ' another embodiment, one or more radiation heater 54 of thermal source 45 ' comprise usually wherein, for example infrared heating element, electromagnetic-energy or similarly radiant heating source.On the one hand, radiation heater 54 can be around the sidewall and

roof

46 and 47 of the radiant chamber 37 of technology controlling and process station 36, is arranged in a plurality of positions or is arranged on the position and orientation of hope, for example, is similar to the layout of convection blowers 51.The same with convection heat sources 52, when foundry goods entered technological temperature control station, the radiation heater of close chamber inlet end can move more promptly to stop the cooling of foundry goods in the sand mold under higher temperature.In addition, vacuum blower, pump or exhaust fans/systems 56 can be connected in radiant chamber to produce negative pressure in radiant chamber 37 by conduit 57.Like this, can in chamber, extract the heat and/or the waste gas of the binding agent burning generation of core and/or sand mold out, thereby avoid the radiation heater element over-temperature.

Technological temperature control station 36 has been shown " another embodiment, wherein show direct impingement heat source 45 " in Fig. 6 A and 6B.This direct impingement heat source comprises and a series ofly is arranged in burner or nozzle 58 on select locations in the radiant chamber 37 or the orientation with group or array way.These burners 58 are connected in fuel source through conduit 59 usually, for example Sweet natural gas etc.Directly the nozzle or the burner element of impingement heat source roughly apply heat towards sidewall, top and the bottom of foundry goods.Therefore, foundry goods is heated full and uniformly, and the sand material that therefrom discharges can also expose with direct heating, so that with its binder material after-flame.

Those skilled in the art will appreciate that these different thermals source can be used in combination in radiant chamber.And a plurality of chambers can be connected and be used to stop the cooling of foundry goods more than the temperature in technological temperature control or this, before foundry goods enters heat treatment station, keep casting temperature thereafter.

On the other hand, the waste gas that produces during casting molten metal can the introducing technology temperature radiant chamber of control station 36, as shown in arrow 60 so that can from the process of heating of metal foundry goods, divide equally heat and recovered energy.On the other hand, because the unnecessary heat that binding agent destruction in the heat treatment station 42 in foundry goods core and/or the sand mold and burning and heat treating castings produce also can turn back to technological temperature control station, shown in the dotted arrow among Figure 1A 61, control the internal medium of the radiant chamber of station to help the heating process temperature.The recovery of this waste gas and heat help to reduce the chamber that technological temperature is controlled station be heated to wish or essential temperature to stop the required energy of foundry goods cooling through chamber.

In addition, shown in Fig. 2 B, 4A, 5A and 6A, along the bottom formation collection funnel or the skewed slot 62 of technological temperature control station 36, it is positioned under the radiant chamber 37.This funnel 62 is usually included in the downward-sloping sidewall 63 in its lower end 64.When binding agent began thermal destruction in technological temperature control station, described sloped sidewall was collected the sand that comes off in foundry goods core and/or the sand mold.Sand flows to downwards on the collection travelling belt 66 under the open lower end that is positioned at funnel 62 usually.Usually place fluidization system or mechanisms 67 along the bottom 64 of the wall of funnel 62.This fluidizer generally includes burner, gas blower, divider or similar fluidisation unit; for example; in U.S. Patent No. 5; 294,994, No.5; 565; 046, No.5,738; open and claimed in 162; its content is hereby incorporated by, and wherein with the medium flow of heating, for example air or other fluids join in the sand; impel tackiness agent further to degrade; thereby the cake broke that helps to make the sand that comes off from foundry goods and binding agent to form, so as to reclaim core and/sand of sand mold, making foundry goods is purified form.The sand that reclaims is collected on the travelling belt 66, and transmits and leave technological temperature control station.

In addition, shown in Figure 1A, 2A, 2B, 4A, 5A and 6A, be used for the unnecessary heat that the burning of foundry goods core and/or sand mold binder material produces and waste gas also can be collected or extract out from the radiant chamber 37 of technological temperature control station 36, and import heat treatment station 42, shown in the arrow among Figure 1A 68.Unnecessary heat and waste gas lead to heat treatment station from technological temperature control station makes the heat that produces in the chamber of technological temperature control station to reclaim, and sand mold and/or binder degradation of sand cores produce waste gas in thermal processing chamber continuation heating and/or burning.Shown in Figure 1A, gas blower or similarly air distribution mechanism 69 further installed usually along heat treatment station, and usually will be in the heat treatment process of foundry goods and the waste gas that produces of the binder material after-flame process of the core of foundry goods and/or sand mold extract out.These waste gas are collected by gas blower, and usually import to these waste gas further handle and incendiary incinerator 71 in, thereby these waste gas are handled again and the amount of pollutants that causes of minimizing foundry goods and thermal treatment process.Can also use strainer to take a step forward and filter the waste gas come from technological temperature control station, and/or filter the gas from the heat treatment station to the incinerator to enter heat treatment station at waste gas.

Therefore, described technological temperature control station is as heat treatment station or the preceding embedding zone of chamber, wait for when entering heat treatment station that wherein foundry goods can be maintained at or be limited in technological temperature control or this more than temperature, but is lower than required thermal treatment temp when foundry goods.Therefore, described system can make casting production line move with faster or more effective speed, and foundry goods needn't be waited in line to send in the heat treatment station being exposed to external environment following time, thereby causes foundry goods to be cooled to below their the technological temperature control.After this, these foundry goods can be independent, as Figure 1A, shown in 1C and the 2A-2B, or in batch, shown in Figure 1B, 1C and 3, is transported in the heat treatment station 42 and heat-treats, and makes described core and/or sand mold breakdown and removal, and reclaim sand in some cases.

Heat treatment station 42 (Fig. 2 B) can be elongated stove, comprises the furnace chamber 75 that one or more is installed continuously, and travelling belt 76 extends through described furnace chamber to carry foundry goods.Thermal source 77 (Fig. 2 A) comprises the source of conductive heating that applies air for example or other fluidic heating mediums, for example gas blower or nozzle, conduction heat sources, fluidized-bed for example, induction, radiation and/or other types thermal source can be installed in the wall and/or roof of chamber 75, be used for providing heat and optional air-flow in various degree with around the foundry goods of quantity, thereby foundry goods is heated to suitable thermal treatment temp.The thermal treatment temp of this hope and heat treatment time will change according to the type of the metal or metal alloy that forms foundry goods, and this is as well known to those skilled in the art.

The example that is suitable for the various heat treatment furnaces that use together with the present invention is included in U.S. Patent No. 5,294, and 994, No.5,565,046 and No.5, those heat treatment furnaces shown in 738,162, its content is hereby incorporated by.The heat treatment furnace that uses with the present invention or another example of station are open and be shown in U.S. Patent No. 6,217,317, the U.S. Patent application No.09/665 that submitted on September 9th, 2000, the U.S. Patent application No.10/051 that on January 18th, 354 and 2002 submitted to, in 666, its content all is incorporated herein by reference at this.This heat treatment station or stove can comprise the structure that is recovered in during the heat treating castings from the sand of core and/or molds dislodged.

After the thermal treatment, foundry goods takes out from heat treatment station usually and moves to quench station 78 (Figure 1A), is used for cleaning and further handling.Described quench station generally includes has cooling fluid, and for example the quenching tank of water or other known coolant maybe can comprise the chamber with series of spray nozzles, described nozzle ejection cooling fluid, for example air, water or similar heat-eliminating medium.Then, taking out foundry goods further cleans as required and handles.

Another embodiment of integrated equipment 5 has been shown in Figure 1B.This equipment 5 comprises the transporting mechanism 27 that is shown as lifting machine or robots arm 28, its with foundry goods from a plurality of pouring product lines or station 11 and 11 ' take off.In this example, described pouring product line or station 11 and 11 ' be shown as the carrousel type system, wherein mold can rotation between cast or casting position 23 and point of delivery 24.Transporting mechanism 27 engages and carries its inside to have the sand mold of foundry goods, or foundry goods taken out from mold and with foundry goods be transported to one or

more travelling belt

34 and 34 that enters the mouth of thermal treatment unit 26 '.These foundry goods can move into individually and introduce in the heat treatment station 42 by technological temperature control station 36, maybe can collect in the basket bucket or in the delivery tray 79, are used for the batch processing foundry goods.

In the example system shown in Figure 1B 5, technological temperature control station 36 forms the elongated radiation pipeline 81 that has defined chamber 82 usually, and the sand mold that foundry goods or its inside accommodate foundry goods can move or transmit through this chamber.Radiation pipeline 81 comprises a series of thermals source 83 along its installation, for example the multiple different heat sources of describing above with reference to the embodiment of Fig. 2 A-2B and 4A-

6B

45,45 ' and 45 ".Usually, the wall 84 of the chamber 82 of radiation pipeline 81 and roof are made or are coated with refractory materials by refractory materials, make the heat that produces in radiation pipeline towards foundry goods reflection and/or radiation.Foundry goods can be collected and/or leave in basket bucket 79 or be arranged in the similar delivery tray of the collection station 86 of radiation pipeline 81 ends.This basket bucket 79 or pallet are used to hold foundry goods and/or the mold by heat treatment station 42.Foundry goods be collected in alternatively be used in the basket bucket foundry goods by technological temperature control station 36 radiant chamber or passage before carry out batch processing in heat treatment station, shown in Fig. 1 C and 3.

In Fig. 1 C, schematically show another embodiment of integrated equipment 5 of the present invention.In this embodiment, technological temperature control station 36 is shown as elongate radiation pipeline or chamber 81 (as described at Figure 1B), connects or sends into refrigerant and remove station 87.This refrigerant removal station 87 links to each other with heat treatment station 42 and foundry goods is sent in the heat treatment station 42.Usually, described foundry goods moves and thermal treatment or processing in remaining in semipermanent or sand mold the time, and wherein said sand mold also comprises " refrigerant " that is installed in wherein.The metal sheet that refrigerant is normally made by steel or analogous material has the design shape (relief) of the required project organization that is used to form cast(ing) surface, and when the casting molten metal material or before this, refrigerant is put into mold.Therefore, before heat treating castings, must take out refrigerant, or reclaim described refrigerant and reuse.After passing through the chamber 82 of radiation pipeline 81, during this period, the burning of sand mold will begin usually at least in part, and refrigerant can take out easily, and can obviously not incur loss through delay moving of mold and foundry goods heat treated station 42.After removing chill removal station at refrigerant, there is the mold of foundry goods directly to send into heat treatment station usually in it and heat-treats, core and sand mold breakdown, and reclaim sand.

Another embodiment of integrated equipment of the present invention has been shown in Fig. 1 D.In this embodiment, foundry goods can from mold, take out and be transported to usually the

inlet travelling belt

90 or 91 be used for directly sending into one or more heat treatment furnace or station 92.Alternatively, if foundry goods forms in sand mold, then whole mold can be transported on one of

inlet travelling belt

90 or 91 from point of delivery 28.Shown in Fig. 1 D, foundry goods takes out from mold and carries foundry goods subsequently, or its inside mold of accommodating foundry goods takes out and be transported to heat treatment station 92 from the cast station, and this can be finished by same transporting mechanism or mechanical arm usually.

In this embodiment, thermal source 93 is installed on the transporting mechanism 27, when foundry goods moves to the inlet travelling belt 90 of heat treatment furnace 92 or one of 91 the time, this thermal source directly applies heat to foundry goods and/or sand mold from the point of delivery of casting production line.As mentioned above, described thermal source can comprise radiation energy, for example infrared or electromagnetic launcher, induction, convection current and/or conduction heat sources, or the thermal source of conspicuous other types for a person skilled in the art.When foundry goods or mold are transported to the inlet travelling belt, come from the heat guiding foundry goods of the thermal source 93 that is installed on the transporting mechanism 27 or one or more surface of mold, for example top and/or side, therefore thereby can stop the cooling of foundry goods and/or mold, the temperature of foundry goods metal be remained essentially in the technological temperature control of this metal or this is more than temperature.

Other thermals source 94 can be installed in

inlet travelling belt

90 and 91 tops or near, shown in Fig. 1 D, or along as arrow 96,96 ', the travel path of the transporting mechanism of 97 and 97 ' indication installs with the maintenance casting temperature.In addition, gas blower, fan or other similar air moving device (not shown) also can be placed near the transporting mechanism, or along as

arrow

96,96 ', 97 and 97 ' shown in the travel path of transporting mechanism place, be used for heating medium, for example the fluid of air or other heating is applied on it.Blowers distribute impose on foundry goods and/or mold heat so that during being sent to heat treatment furnace 92 from pouring product line the inhomogeneous heating or the cooling of foundry goods minimize.Use this being installed on the transporting mechanism, and thermal source or the heating unit installed along the travel path of foundry goods in some device can realize the function of technological temperature control station, thereby help to stop the cooling of foundry goods and make foundry goods remain on technological temperature control or this is more than temperature.

Fig. 3 has shown another embodiment of the present invention.In this example, foundry goods and/or sand mold can be placed directly in by transporting mechanism 27 and collect in basket bucket or the delivery tray 100, and are transported to and are used for process of thermal treatment temperature control station in batches.In this device; foundry goods 12 is packed in a series of cabins or chamber 101 of delivery tray 100 usually; its medium casting is placed on known indexing position; enter and during with convenient foundry goods by technological temperature control station 102 and heat treatment station 103; can directly apply the heat of decoring or other functions; as the U.S. Patent application No.09/665 that on September 9th, 2000 submitted to, 354 is disclosed and claimed, and its content is hereby incorporated by.In this embodiment, when foundry goods was packed into, pallet 100 common calibration entered and leave the chamber 104 of technological temperature control station, as arrow 106 and 106 ' shown in.As a result, the exposure of foundry goods in external environment minimized, simultaneously in each other cabin 101 of pallet remaining foundry goods in this batch is housed, the exposure in boundary's environment outside of its medium casting will make foundry goods be cooled to that technological temperature is controlled or critical temperature under.

In addition, as shown in Figure 3, can also provide directed thermal source 107 for each cabin 101 of pallet 100.For example, when first cabin 101 ' in foundry goods 12 ' and calibration when entering technological temperature control station 102 is housed, the foundry goods and/or the sand mold guiding heat of first thermal source 107 ' to being arranged in specific cabin.Then, when follow-up foundry goods or mold were packed other chambers of basket bucket or cabin into, the additional heating source 107 in these cabins of leading was started working.Therefore, the heating of the chamber 104 of the technological temperature control station specific region that can be limited in as required or lead is so that more effectively heat foundry goods.

As shown in Figure 3, a series of gas blowers or other similar air moving device 108 can be installed to the top of technological temperature control station, are used to extract out the waste gas of core and/or sand mold binder material degraded generation.Subsequently, gas and used heat import heat treatment station 103 by conduit 109, carry out heat recuperation and pollution abatement, and help avoid combustible waste and gather at the side and the top of technological temperature control station 102 chambers.

Therefore, it should be appreciated by those skilled in the art that according to detailed description above, the present invention has application widely.Under the situation that does not break away from the present invention essence and scope, the of the present invention many remodeling except description herein, and many variations, modification and equivalent arrangements will become apparent or rationally by the present invention and foregoing detailed description.

Although invention has been described at particular aspects herein, should be appreciated that just the present invention's explanation and exemplary of this detailed description, and just disclose purpose of the present invention and make for providing abundant.The detailed description of Chan Shuing herein both had been not used in restriction the present invention and had not also got rid of any other this class embodiment of the present invention, remodeling, distortion, modification and equivalent arrangements, and the present invention only is limited to claims and equivalence is described.

Claims

1. system that is used to form with the heat-treated metal foundry goods, this system comprises:

Be positioned the technological temperature control station of heat treatment station upstream, described technological temperature control station comprises the temperature sensing device that links to each other with thermal source,

Wherein said temperature sensing device links to each other with the technological temperature control that casting temperature is remained on the foundry goods metal with described thermal source or this is more than temperature.

2. the system as claimed in claim 1, wherein said technological temperature control station also comprises the controller that links to each other with described thermal source with described temperature sensing device, and the heat that described controller control imposes on foundry goods controls with the technological temperature that casting temperature is remained on the foundry goods metal or this is more than temperature.

3. the system as claimed in claim 1, wherein said thermal source applies enough heats stoping the foundry goods cooling to foundry goods, and foundry goods is not heated to more than the thermal treatment temp of foundry goods metal.

4. the system as claimed in claim 1, wherein said technological temperature control is lower than the thermal treatment temp of foundry goods metal.

5. the system as claimed in claim 1, wherein said technological temperature control is a temperature, under this temperature, the every reduction of casting temperature one minute just need be carried out thermal treatment more than one minute to reach the foundry goods character of hope.

6. the system as claimed in claim 1, wherein said technological temperature control is a temperature, under this temperature, the every reduction of casting temperature one minute just need be carried out at least about four minutes thermal treatment to reach the foundry goods character of hope.

7. the system as claimed in claim 1, wherein said metal is aluminium/copper alloy, and technological temperature is controlled to be about 400 ℃-about 470 ℃.

8. the system as claimed in claim 1, wherein said metal is an iron alloy, and technological temperature is controlled to be about 1000 ℃-about 1300 ℃.

9. system that is used to form with the heat-treated metal foundry goods, this system comprises:

Heat treatment station, it comprises the heat treatment furnace with foundry goods inlet region;

Be positioned at the temperature measuring equipment of described inlet region; With

The transporting mechanism that links to each other with described temperature measuring equipment;

Wherein when detecting exhaust temperature by described temperature measuring equipment, described transporting mechanism was removed this foundry goods before foundry goods enters described stove.

10. system as claimed in claim 9, wherein exhaust temperature is following about 10 ℃-about 20 ℃ of the technological temperature control of foundry goods metal, wherein technological temperature is controlled to be a temperature, under this temperature, the every reduction of casting temperature one minute just need be carried out thermal treatment more than one minute to reach the foundry goods character of hope.

11. system as claimed in claim 9, wherein said exhaust temperature is following about 10 ℃-about 20 ℃ of a heat treatment furnace temperature.

12. an integrated equipment that is used to form with the heat-treated metal foundry goods, this equipment comprises:

The cast station is used for poured with molten metal to mold to form foundry goods;

Be positioned at the technological temperature control station in described cast station downstream, described technological temperature control station comprises the temperature sensing device that links to each other with transporting mechanism with thermal source; With

Be positioned at the heat treatment furnace of described technological temperature control station upstream;

Wherein said temperature sensing device and described thermal source are suitable for that casting temperature is remained on the technological temperature control of foundry goods metal or this is more than temperature; With

Wherein when the discharging signal that receives from described temperature sensing device, described transporting mechanism was removed foundry goods before foundry goods enters described stove.

13. integrated equipment as claimed in claim 12, wherein said technological temperature control station also comprises the controller that links to each other with described thermal source with described temperature sensing device, and the heat that described controller control imposes on foundry goods controls with the technological temperature that casting temperature is remained on the foundry goods metal or this is more than temperature.

14. integrated equipment as claimed in claim 12, wherein said transporting mechanism receives the discharging signal about 10 ℃-about 20 ℃ the time at casting temperature below following temperature:

(a) technological temperature of foundry goods metal control, wherein said technological temperature control is a temperature, under this temperature, the every reduction of casting temperature one minute just need be carried out thermal treatment more than one minute reaching the foundry goods character of hope, or

(b) temperature of heat treatment furnace.

15. a method that forms foundry goods, this method has the heat treatment time of minimizing, and this method comprises:

With poured with molten metal in the mold to form foundry goods;

Monitor casting temperature;

Casting temperature and the control of predetermined technological temperature are compared;

If described casting temperature is lower than described technological temperature control, apply heat for described foundry goods;

Described foundry goods is put into heat treatment furnace; And

Described foundry goods is heat-treated.

16. method as claimed in claim 15 wherein applies heat to described foundry goods and comprises that applying enough heats to described foundry goods allows molten metal to solidify to remain on the control of described technological temperature or this temperature at casting temperature when above.

17. method as claimed in claim 15, the control of wherein said technological temperature is a temperature, and under this temperature, the every reduction of casting temperature one minute just need be carried out thermal treatment more than one minute to reach the foundry goods character of hope.

18. the method for formation and thermal treatment foundry goods, this method comprises:

With poured with molten metal in the mold to form foundry goods;

Monitor casting temperature;

Casting temperature and predetermined exhaust temperature are compared,, discharge described foundry goods if described temperature is equal to or less than described exhaust temperature;

Casting temperature and the control of predetermined technological temperature are compared, be lower than described technological temperature control if described temperature is higher than described exhaust temperature, apply heat for described foundry goods; With

Described foundry goods is heat-treated.

19. method as claimed in claim 18, wherein said exhaust temperature is that the technological temperature of foundry goods metal is controlled following about 10 ℃-about 20 ℃, wherein said technological temperature is controlled to be a temperature, under this temperature, the every reduction of casting temperature one minute just need be carried out thermal treatment more than one minute to reach the foundry goods character of hope.

20. method as claimed in claim 18, wherein said exhaust temperature are following about 10 ℃-about 20 ℃ of heat treatment furnace temperature.