JP5689403B2 - Integrated metal processing equipment - Google Patents

Description

Traditionally, in a conventional process for forming a metal casting mold, for example, mold or sand mold having an internal chamber exterior features of a desired casting is defined, is filled with thaw metal. Arranged or sand core defining internal features of the casting is received within the mold, as thaw metal solidifies around the core, internal details of the casting is formed. After thawing the metal of the casting has solidified, the casting is moved to a generally treatment furnace. This is because the casting is heat treated to remove the sand from the sand core and / or mold and perform other processing as required. The heat treatment process adjusts the casting metal or metal alloy to achieve the desired physical properties for a given application.

Typically, the casting may be exposed to the foundry or ambient environment of the metalworking facility while the casting is transferred from the casting station to the heat treatment station, and particularly if the casting is left for a significant amount of time. . As a result, castings tend to rapidly cool the thaw or semi thaw temperature. A certain amount of cooling of the casting is necessary to solidify the casting, but the temperature of the casting is further reduced and the casting is below the process critical temperature (also referred to herein as “process control temperature”). As the residence time increases, the time required to heat the casting to a desired heat treatment temperature and heat treat the casting increases. For example, with certain metals, an extra heat treatment time of at least about 4 minutes is required for each minute that the casting temperature falls below its process control temperature to achieve the desired result. It was discovered that Thus, to achieve the desired physical properties, an additional heat treatment time of at least about 40 minutes is required even if the casting metal temperature drops below the process control temperature for 10 minutes. Thus, typically, the casting is heat treated for 2-6 hours, and in some cases longer, to achieve the desired heat treatment effect. This results in greater energy utilization and therefore higher heat treatment costs.

(Summary)
Briefly described, the present invention generally comprises an integrated metal processing facility for pouring, forming, heat treating, and further processing castings formed from metals or metal alloys. Integrated metal processing facility typically includes thaw metal, e.g., aluminum or iron or a metal alloy mold or die, for example, a permanent mold, the pouring station is injected into the semi-permanent mold or sand mold. The mold is transitioned from the pouring or casting position of the casting station to the transfer position. In the transfer position, the casting is removed from the mold or transferred to the heat treatment line. The transfer mechanism typically includes a robot arm, crane, overhead hoist or lift, propeller, conveyor, or similar transport mechanism. Further, the same mechanism may be used to remove the casting from the mold and transfer the casting to the heat treatment line. During this transition from the pouring station to a transfer position and / or heat treatment line, thaw metal castings are cooled to a sufficient extent to form a casting.

  A heat treatment line or unit is generally located at a process temperature control station, typically a heat treatment station or furnace having one or more furnace chambers, and optionally generally downstream of the heat treatment station. Includes quenching station. The process temperature control station is typically a long chamber or tunnel through which castings are received before being introduced into the heat treatment station. The chamber may include a series of heat sources, such as radiant heaters, infrared, induction, convection, conduction, or other types of heating elements. The walls and ceilings of the process temperature control station may further include radiant material that tends to radiate or direct heat to the castings and / or molds as they pass through the chamber. Alternatively, when a casting or mold is transferred from a casting station to a heat treatment station, a series of heat sources, including radiant heating elements, such as infrared and induction heating elements, convection, conduction, or other types of heat sources, is used in the casting or mold. May be used to direct heat. In addition, a heating element or heat source can be directly attached to the transfer mechanism to heat the casting and / or sand mold.

  As the casting and / or casting-containing mold passes through the process temperature control station, the cooling of the casting is blocked to a process control temperature or higher. The process control temperature is generally below the solution heat treatment temperature required for the cast metal, and the casting is cooled to an amount or degree sufficient to solidify, but below that, The time required to heat treat the casting after raising the casting to the solution heat treatment temperature increases exponentially. The casting is maintained at or above the process control temperature until entering the heat treatment station.

  By preventing the casting from cooling and then maintaining the casting at a temperature substantially above or above the casting metal process control temperature, the time required to heat treat the casting can be significantly reduced. Thus, the casting station power of the casting can be increased and the overall processing and heat treatment time of the casting can be shortened.

The casting passes through the inlet area before entering the heat treatment furnace. The temperature of the casting is monitored to determine if the temperature has dropped below a preset or predefined rejection temperature. If the casting temperature is less than or equal to the rejection temperature, the casting may be removed from the heat treatment line using any suitable means. If the casting is accepted, it goes to a heat treatment furnace for heat treatment.

  The heat treatment unit may include features that aid in the removal and / or regeneration of the sand core and / or mold. Thereafter, the casting may undergo additional processing, such as quenching, aging, and / or further heat treatment.

Various objects, features and advantages of the present invention will become apparent to those skilled in the art upon review of the following detailed description in conjunction with the accompanying drawings.
For example, the present invention provides the following.
(Item 1)
A system for forming and heat treating a metal casting,
With a process temperature control station located upstream of the heat treatment station and including a temperature detector in communication with the heat source;
The temperature detector and the heat source communicate to maintain the casting temperature at or above the casting metal process control temperature;
system.
(Item 2)
The process temperature control station further comprises a controller in communication with the temperature detector and the heat source, wherein the controller controls the amount of heat applied to the casting to a cast metal process control temperature or above. The system according to item 1, wherein the temperature of the casting is maintained.
(Item 3)
The system of item 1, wherein the heat source applies sufficient heat to the casting to prevent cooling of the casting without heating the casting beyond the heat treatment temperature of the casting metal.
(Item 4)
The system according to item 1, wherein the process control temperature is lower than the heat treatment temperature of the cast metal.
(Item 5)
Item where the process control temperature is below that temperature at which a heat treatment of more than one minute is required to obtain the desired properties of the casting every minute that the casting temperature decreases. The system according to 1.
(Item 6)
Below that temperature, the process control temperature is such that at least about 4 minutes of heat treatment is required to obtain the desired properties of the casting every minute that the casting temperature decreases. The system according to item 1.
(Item 7)
The system of claim 1, wherein the metal is an aluminum / copper alloy and the process control temperature is from about 400C to about 470C.
(Item 8)
The system of item 1, wherein the metal is an iron alloy and the process control temperature is from about 1000C to about 1300C.
(Item 9)
A system for forming and heat treating a metal casting,
A heat treatment station including a heat treatment furnace having a casting inlet area;
A temperature measuring device in the inlet area;
A transfer mechanism in communication with the temperature measuring device,
When the temperature measuring device detects a rejection temperature, the transfer mechanism removes the casting before entering the furnace.
(Item 10)
The reject temperature is about 10 ° C. to about 20 ° C. below the process control temperature of the cast metal, and below the process control temperature, every minute of the time that the temperature of the casting decreases, the casting 10. The system of item 9, wherein the system is at a temperature that requires more than 1 minute of heat treatment to obtain the desired properties of.
(Item 11)
10. The system of item 9, wherein the rejection temperature is about 10 ° C. to about 20 ° C. below the temperature of the heat treatment furnace.
(Item 12)
An integrated facility for forming and heat-treating metal castings,
A pouring station to form a casting by injecting thaw metal into the mold,
A process temperature control station downstream of the casting station and including a temperature detector in communication with a heat source and a transfer mechanism;
A heat treatment furnace upstream of the process temperature control station,
The temperature detector and the heat source are configured to maintain the temperature of the casting at or above the process control temperature of the casting metal;
When the transfer mechanism receives a rejection signal from the temperature detection device, the casting before removing the casting before entering the furnace.
(Item 13)
The process temperature control station further comprises a controller in communication with the temperature detector and the heat source, wherein the controller controls the amount of heat applied to the casting to provide a process control temperature at or above the casting metal. 13. The integrated facility of item 12, wherein the temperature of the casting is maintained at the temperature.
(Item 14)
The casting temperature is
(A) When the process control temperature is lower than that, at a temperature at which a heat treatment exceeding 1 minute is required every 1 minute during which the temperature of the casting is lowered, in order to obtain the desired properties of the casting. 13. The integrated facility of item 12, wherein the transfer mechanism receives a rejection signal when the process control temperature of the cast metal in some cases, or (b) about 10 ° C. to about 20 ° C. below the temperature of the heat treatment furnace .
(Item 15)
A method of forming a casting having a reduced heat treatment time, comprising:
Forming a casting by injecting thaw metal into the mold,
Monitoring the temperature of the casting,
Comparing the temperature of the casting with a predetermined process control temperature;
The step of applying heat to the casting if the casting temperature is lower than the process control temperature;
A method comprising: placing a casting in a heat treatment furnace; and heat treating the casting.
(Item 16)
Step of applying heat to the castings, enough heat in addition to casting, comprising the step of maintaining the temperature of the casting to the process control temperature or above the temperature, thaw metal to be solidified, Item 16. The method according to Item15.
(Item 17)
Item where the process control temperature is below that temperature at which a heat treatment of more than one minute is required to obtain the desired properties of the casting every minute that the casting temperature decreases. 15. The method according to 15.
(Item 18)
A method of forming and heat treating a casting,
Forming a casting by injecting thaw metal into the mold,
Monitoring the temperature of the casting,
Comparing the casting temperature with a predefined rejection temperature and rejecting the casting if the temperature is less than or equal to the rejection temperature;
Comparing the temperature of the casting with a predetermined process control temperature, and if the temperature is higher than the rejection temperature but lower than the process control temperature, the method includes the steps of applying heat to the casting and heat treating the casting .
(Item 19)
The rejection temperature is about 10 ° C. to about 20 ° C. below the process control temperature of the cast metal, and at temperatures below the process control temperature, every minute of the time that the casting temperature decreases, 19. A method according to item 18, wherein the temperature is such that a heat treatment of more than 1 minute is required to obtain the desired properties of the casting.
(Item 20)
19. The method of item 18, wherein the rejection temperature is about 10 ° C to about 20 ° C below the temperature of the heat treatment furnace.

FIG. 1A is a schematic illustration of an exemplary metal processing system in accordance with various aspects of the present invention. FIG. 1B is a schematic illustration of another exemplary metalworking system illustrating collecting and transferring castings from multiple casting stations to a heat treatment unit in accordance with various aspects of the present invention. FIG. 1C is a schematic illustration of another exemplary metal processing system for removing chill from a mold in accordance with various aspects of the present invention. FIG. 1D is a schematic illustration of yet another exemplary system in accordance with various aspects of the present invention, illustrating a transfer mechanism including a heating device. FIG. 2A is a plan view of an exemplary process temperature control station and heat treatment station in accordance with various aspects of the present invention. FIG. 2B is a side view of the process temperature control station and heat treatment station shown in FIG. 2A. FIG. 3 is a perspective view of an exemplary lot processing system in accordance with various aspects of the present invention. 4A and 4B illustrate an exemplary process temperature control station that includes a convective heat source in accordance with various aspects of the present invention. 4A and 4B illustrate an exemplary process temperature control station that includes a convective heat source in accordance with various aspects of the present invention. 5A and 5B illustrate another exemplary process temperature control station that includes a direct heat / incident heat source in accordance with various aspects of the present invention. 5A and 5B illustrate another exemplary process temperature control station that includes a direct heat / incident heat source in accordance with various aspects of the present invention. 6A and 6B illustrate another exemplary process temperature control station that includes a radiant heat source in accordance with various aspects of the present invention. 6A and 6B illustrate another exemplary process temperature control station that includes a radiant heat source in accordance with various aspects of the present invention.

(Detailed explanation)
Reference will now be made in detail to the drawings. Like numbers refer to like parts throughout the several views. 1A-3 schematically illustrate an exemplary integrated metal processing facility or system 5 and method for processing metallurgical castings. Metal casting processes are generally known to those skilled in the art, and conventional casting processes are only briefly described for reference purposes. As will be appreciated by those skilled in the art, the present invention can be used in any type of casting process. Such processes include metal casting processes that form aluminum, iron, steel, and / or other types of metal and metal alloy castings. Thus, the present invention is not, and should not be limited to, be used with a particular casting process or a particular type of metal or metal alloy.

As shown in FIG. 1A, thaw metal or typically metal alloy M is injected into the die or mold 10 by pouring or casting station 11, casting 12, for example, a cylinder head, engine block or similar cast, A part is formed. A casting core 13 formed from sand and an organic binder, such as a phenolic resin, is received or placed in the mold 10 to create hollow cavities and / or casting details or core receivers in the casting. Alternatively, each of the molds may typically be a permanent mold or die formed from a metal, such as steel, cast iron, or other material, as is known in the art. Such a mold may have a clamshell type structure to facilitate opening and removal of the casting. Further alternatively, the mold may be a “precision sand mold” type mold and / or a “green mold”. These are generally similar to the sand casting cores 13, such as sand materials mixed with binders known in the art, such as phenolic resins or other binders, such as silica sand or zircon. Formed from sand. The mold may further be a semi-permanent sand mold. Semi-permanent sand molds typically have an outer mold wall formed from sand and binder material, metal, such as steel, or a combination of both types of materials.

  As will be appreciated, the term “template” will now generally refer to all types of templates described above. Among such molds are permanent or metal dies, semi-permanent and precision sand molds, and other metal casting molds, except where specific types of molds are indicated. As will be further appreciated, in the various embodiments described below, the present invention is not limited to castings removed from permanent molds, or heat treatments, sand molds, unless specific types of molds and / or heat treatment processes are indicated. It can be used to heat treat the casting remaining in the sand mold to combine cracking and sand reclamation.

As shown in FIG. 1A, each of the molds 10 generally includes a sidewall 14, an upper wall or top 16, and a lower wall or bottom 17. These collectively define the internal cavity 18. Thawing metal is received within the internal cavity, it is formed into casting 12. Injection opening 19 is generally formed in each of the mold of the upper wall or top 16, in communication with the internal cavity, thaw metal into the internal cavity 18 through each of the mold at the pouring station 11 Pass through. As shown in FIG 1A~ Figure 1C, pouring station 11 generally includes a ladle or similar mechanisms 21 for injecting the thaw metal M into the mold. The casting station 11 further includes a conveyor 22, such as a carousel, piston, indexing, or similar transport mechanism. Transport mechanism, thaw metal moves one or more templates to the transfer point or transfer position 24 from the the injection or casting position 23 injected into the mold. At the transfer point or transfer position 24, the casting is removed from the mold or the mold containing the casting is transferred from the casting station to the heat treatment unit 26 or heat treatment line. After thawing metal is injected into the mold, the mold is conveyed to the transfer position. In the transfer position, the metal is cooled to the desired range or temperature in the die to the extent necessary for the metal to solidify into the casting. The casting is then heat treated at the desired heat treatment temperature.

  As the casting metal cools, it reaches a temperature or temperature range, referred to herein as the “process control temperature” or “process critical temperature”, at which the casting is raised to the heat treatment temperature to effect heat treatment. It has been discovered that the time required to perform increases significantly. As will be appreciated by those skilled in the art, the process control temperature of a casting being processed according to the present invention depends on the particular metal and / or metal alloy used in the casting, the size and shape of the casting, and a number of other factors. Varies depending on

  In one aspect, the process control temperature may be about 400 ° C. for some alloys or metals. In other aspects, the process control temperature may be from about 400 ° C to about 600 ° C. In other aspects, the process control temperature may be from about 600 ° C to about 800 ° C. Further, in other aspects, the process control temperature may be from about 800 ° C to about 1100 ° C. Further, in other aspects, the process control temperature may be from about 1000 ° C. to about 1300 ° C. for some alloys or metals, such as iron. In one particular example, the aluminum / copper alloy may have a process control temperature of about 400 ° C. to about 470 ° C. In this example, the process control temperature is generally below the solution heat treatment temperature for most copper alloys, typically from about 475 ° C to about 495 ° C. Although specific examples have been provided herein, the process control temperature depends on the particular metal and / or metal alloy used in the casting, the size and shape of the casting, and a number of other factors, It will be understood that any temperature may be used.

  When the casting metal is within the desired process control temperature range, the casting is typically sufficiently cooled and solidified as desired. However, if the casting metal is cooled below its process control temperature, additional heating of the casting for at least about 4 minutes for each minute that the casting metal is cooled below the process control temperature, It has been discovered that it is necessary to reach the desired heat treatment temperature, for example, about 475 ° C to about 495 ° C for an aluminum / copper alloy and about 510 ° C to about 570 ° C for an aluminum / magnesium alloy. Thus, if the casting is cooled below the process control temperature for only a short time, the time required to properly and completely heat treat the casting is significantly increased. Further, it should be understood that in a lot processing system where several castings are processed in a heat treatment station as a single lot, for example as shown in FIGS. 1B, 1C, and 1D, the entire lot of castings The heat treatment time is generally based on the heat treatment time required for the casting having the lowest temperature in the lot. As a result, if one of the castings in the lot being processed is cooled to a temperature below the process control temperature, for example for 10 minutes, typically the entire lot for at least an additional 40 minutes, for example. Must be heat treated to ensure that all of the casting is properly and completely heat treated.

Accordingly, various aspects of the present invention are directed to an integrated processing facility or system 5 (FIGS. 1A-3) and method for processing metal castings. Various systems, to a temperature above which the process control temperature or metals to prevent the cooling of the thaw metal, or equal to the desired heat treatment temperature, while it from the set to be below solidifying the casting, casting Designed to move and / or transition castings (in or away from the mold) from the station 11 to the heat treatment system or unit 26. Accordingly, various aspects of the present invention include a system that monitors the temperature of the casting to ensure that the casting is substantially maintained at or above the process control temperature. For example, a thermocouple or other similar temperature detection device or system is placed on or adjacent to the casting or at a location spaced along the path the casting moves from the casting station to the heat treatment furnace. Substantial continuous monitoring can be provided. Alternatively, periodic monitoring of time intervals determined to be of sufficient frequency may be used. Such an apparatus may be in communication with a heat source such that the temperature measurement or detection device and the heat source cooperate to maintain the casting temperature substantially at or above the casting metal process control temperature. As will be appreciated, the temperature of the casting is measured at one specific location on or in the casting, or an average temperature calculated by measuring the temperature at multiple locations on or in the casting. It may be measured in other ways as required or desired in a particular application. Thus, for example, the temperature of the casting may be measured at multiple locations on or in the casting, and the overall temperature value is the lowest temperature detected, the highest temperature detected, the median temperature detected, It may be calculated or determined as a detected average temperature, or any combination or variation thereof.

Further, the casting may pass through the entrance or rejection area 110 before entering the heat treatment furnace. In region 110, the temperature of each casting is monitored to determine if the casting has been cooled to a range that requires an excessive amount of energy to raise the temperature to the heat treatment temperature. The inlet area may be included in the process control temperature station or may be a separate area, as schematically shown in the various figures. The casting temperature is monitored by any suitable temperature sensing or measuring device, such as a thermocouple, to determine whether the casting temperature has reached or dropped below a preset or pre-defined rejection temperature. In one aspect, the predefined rejection temperature may be a temperature below the process control temperature of the casting metal (eg, by about 10 ° C. to about 20 ° C.). In other aspects, the predefined rejection temperature may be a temperature below the heat treatment temperature of the heat treatment furnace or furnace (eg, by about 10 ° C. to about 20 ° C.). If casting is cooled to a temperature below than or equal to previously specified temperature, the control system may send a rejection signal to the transfer or removal mechanism. In response to detection of a defect condition or signal, the subject casting may be identified for further evaluation or removed from the transfer line. The casting may be removed by any suitable mechanism or device including, but not limited to, a robotic arm or other automated device, or may be removed manually by an operator.

  As mentioned above, the temperature of the casting is measured at one specific location on or in the casting or is an average temperature calculated by measuring the temperature at multiple locations on or in the casting. It will be understood that it may be measured in any other way required or desired in a particular application. Thus, for example, the temperature of a casting may be measured at multiple locations on or in the casting, and the overall value is the lowest temperature detected, the highest temperature detected, the median temperature detected, the detected temperature It may be calculated or determined to be an average temperature, or any combination or variation thereof.

  A first embodiment of an integration facility 5 and process for moving and / or processing castings is shown in FIGS. 1A, 2A, and 2B. 1B and 3 show an additional alternative embodiment of an integrated facility 5 and process for forming and processing castings. In this alternative embodiment, castings are collected in a lot processing type array and processed via heat treatment. However, it will be appreciated by those skilled in the art that the principles of the present invention are equally applicable to lot-type equipment, and equipment, and therefore continuous processing type equipment, through which the castings are individually machined. I will. Accordingly, the embodiments described below are not limited to, and should not be limited to, continuous type or lot type processing facilities. 1C and 1D show a further alternative embodiment of the present invention that performs additional processing steps, such as chill removal from the casting (FIG. 1C) and casting casting to multiple heat treatment furnaces (FIG. 1D). . Moreover, as will be appreciated by those skilled in the art, various features of the embodiments described and illustrated below can be combined to form additional embodiments of the invention.

  In the exemplary system shown in FIGS. 1A, 2A, and 2B, the casting 12 is typically removed from the mold 10 at the transfer or casting station 11 by a transfer mechanism 27. As shown in FIGS. 2A and 2B, the transfer system or mechanism 27 typically includes a robot arm or crane 28. However, as will be appreciated by those skilled in the art, various other systems and devices for moving castings and / or molds, such as overhead booms or hoists, conveyors, push rods, or other similar material handling mechanisms are also used. Is possible. As shown in FIGS. 1A, 1B, and 2A, the robotic arm 28 generally includes an engagement or gripper or clamp 29 that engages and holds a mold or casting, and arrows 32 and 32 ′ (FIG. As shown in 2A), a platform 31 is included that allows the arm 28 to be pivotally moved between the transfer point 24 of the casting station and the heat treatment line. Further, as shown in FIG. 1B, the transfer mechanism can be used to transfer molds and / or castings from a plurality of casting stations 11 and 11 ′, and molds to a plurality of heat treatment lines or units 26 (FIG. 1C). And / or castings can be transferred.

  The mold containing the casting is typically moved from the casting station 11 to a pick-up or transfer point 24 (FIG. 2A). At the transfer point 24, the transfer mechanism 27 typically picks up the mold containing the casting or removes the casting 12 from the mold and transports the casting to the heat treatment unit 26. Thus, the same manipulator or transfer mechanism can be used to remove the casting from the casting station and introduce the casting into the heat treatment unit. Typically, a heat source or heating element 33 is positioned adjacent to the casting transfer point 28 to apply heat to the casting. The heat source can typically include any type of heating element or heat source, eg, conduction, radiation, infrared, conduction, convection, and direct incidence type heat sources. As shown in FIG. 2A, a plurality of heat sources 33 can be used to arrange heat most effectively during the transfer operation from the casting station to the heat treatment line.

  Typically, as shown in FIG. 1D, in the case of a permanent or metal die or mold, the mold is opened at the transfer point and the casting is removed by the transfer mechanism. The transfer mechanism then transfers the casting to one or more inlet conveyors 34 (FIGS. 1B and 2A) of the heat treatment unit, line, or system 26 of the integrated processing facility 5. As the mold is opened and the casting is removed, heat source 33 (FIG. 2A) applies heat directly to the casting to prevent or control the cooling of the casting while it is exposed to the foundry or plant environment. This is because the casting is being transferred to the heat treatment unit, so that the casting is maintained substantially at or above the process control temperature of the casting metal.

  For the processing of castings that are semi-permanent or formed in a sand mold, the casting typically remains in the mold during heat treatment, and the mold remains during heat treatment due to thermal degradation of the binder material holding the sand. Therefore, the transfer mechanism 27 transfers the entire mold including the casting from the transfer point to the entrance conveyor 34. Thus, the heat source 33 continues to apply heat to the mold itself, and the amount of heat applied maintains the temperature of the casting in the mold substantially above or above the process control temperature of the cast metal, Controlled to avoid excessive or premature degradation.

  After this, when a reference is made to transport, heat, process, or move or process the “casting”, unless otherwise indicated, such an explanation will be used to remove the single casting excluding the mold. And processing, and U.S. Pat. Nos. 5,294,994, 5,565,046, 5,738,162, 6,217,317, and filed September 9, 2000 As disclosed in pending US patent application Ser. No. 09 / 665,354 and pending US patent application Ser. No. 10 / 051,666 filed Jan. 18, 2002. It is understood that this includes both core decomposition and the process by which the casting remains in the sand mold for sand regeneration. The disclosures of these patents and patent applications are hereby incorporated by reference in their entirety.

  As shown in FIGS. 1A, 2A, and 2B, the casting is initially pre-chambered or process temperature controlled station or module by inlet conveyor 34 (FIGS. 2A and 2B) or conveyors 34 and 34 ′ (FIG. 1B). 36 is indexed or conveyed. As shown in FIGS. 2A and 2B, a process temperature control station or module generally includes a heated inner chamber 37 through which castings and / or molds containing castings pass through the inner chamber 37 and chain. It is transported along a processing path of a heat treatment line on a conveyor, roller, or similar transport mechanism 38. The casting enters the chamber 37 at the upstream or inlet end 39 and exits the chamber 37 via the downstream or outlet end 41 and is generally introduced directly into the heat treatment furnace or station 42 of the heat treatment line 26. The process temperature control station inlet and outlet ends 39 and 41 are open or include doors or similar closure structures as shown at 43 in FIG. Heat loss can be prevented. Typically, the casting is sent directly from the process temperature control station 36 into the heat treatment station 42. The heat treatment station and process temperature control station can be connected to further prevent potential loss of heat and share heat if desired.

  Chamber 37 is generally a radiant chamber and includes a series of heat sources 45. A heat source 45 is mounted in the radiation chamber and is disposed along the chamber wall 46 and / or the ceiling 47. Typically, a plurality of heat sources 45 are used and include one or more different types of heat sources or heating elements. Among the heat sources or heating elements are radiant heat sources such as infrared, electromagnetic and inductive energy sources, conduction, convection and direct incidence type heat sources such as gas fired burner tubes that introduce a flame of gas into the chamber Is included. Furthermore, the side walls and ceiling of the radiant chamber 37 may be formed from or covered with a high temperature radiant material, for example, a metal, metal film or similar material, ceramic, or a composite material capable of radiating heat. . Radiant coatings generally form non-stick surfaces on walls and ceilings. As chamber walls and ceilings are heated, the walls and ceilings tend to radiate heat towards the casting, while the surface is generally from the burning of sand molds and / or core binders. Heated to a temperature sufficient to burn off waste gases and residues, such as firewood, preventing it from collecting and accumulating on the walls and ceilings of the room.

  4A-6B illustrate various exemplary process temperature control stations. 4A and 4B illustrate a process temperature control station 36 that includes a convection type heat source 45. Each of the convective heat sources typically includes one or more nozzles or blowers 51 connected to a source of heat medium by a conduit 52. In this aspect, the blower 51 is arranged or arranged around the ceiling 47 and the side wall 46 of the chamber 37 to transfer a heat medium, such as air or other gas and / or fluid, into the chamber and the castings contained in the chamber. And / or directed towards the mold. Convection blowers generally tend to create a turbulent thermal fluid flow around the casting, as indicated by arrow 53, and apply heat to substantially all sides of the casting and / or sand mold. As a result, the temperature of the casting is maintained substantially at or above the process control temperature of the metal. Furthermore, when the casting is processed in a sand mold, heating in the process temperature control station tends to heat the mold, raising the mold temperature towards the decomposition or combustion temperature. At the decomposition or combustion temperature, the binder material in the mold begins to burn, pyrolyze, or be expelled.

  In other aspects, the blower or nozzle 52 is positioned adjacent to its inlet end in front of the process temperature control station and operates at a higher speed and / or temperature to further cool the casting and / or mold. Stop quickly. Facing the center and / or end of the chamber, for example, a nozzle or blower 52 located at the exit of the process temperature control station can be operated at lower temperatures and speeds to prevent complete degradation of the sand mold, At the same time, the casting can be solidified.

  Alternatively, FIGS. 5A and 5B show another exemplary process temperature control station 36 '. At station 36 ', heat source 45' typically includes one or more radiant heaters 54, such as infrared heating elements, electromagnetic energy sources, or similar radiant heat sources. In one aspect, the radiant heaters 54 are arranged in multiple locations or as a set of desired locations and orientations around the walls 46 and ceiling 47 of the radiant chamber 37 of the process temperature control station 36. This is similar to the arrangement of convection blowers 51, for example. Similar to the convective heat source 52, the radiant heater adjacent to the inlet end of the chamber can operate at a higher temperature and more quickly prevents cooling of the casting in the sand mold as the casting enters the process temperature control station. . In addition, a vacuum blower, pump, or exhalation fan / system 56 is connected to the radiation chamber via conduit 57 to create a negative pressure in the radiation chamber 37. In that case, heat and / or waste gas generated from the burning or burning of the sand core and / or sand mold binder is withdrawn from the chamber, preventing overheating of the radiant heating element.

  In addition, another exemplary process temperature control station 36 "is provided in Figures 6A and 6B. These figures show a direct incident type heat source 45". The direct incident heat source includes a series of burners or nozzles 58 arranged as a set or array in a selected position or orientation within the radiant chamber 37. These burners 58 are typically connected by a conduit 59 to a fuel source, such as natural gas. The nozzle or burner element of the direct incident heat source conducts and applies heat substantially toward the side, top and bottom of the casting. Thus, the casting is heated substantially uniformly, and the sand material released from the casting is further exposed directly to heat, and the binder material is burned off.

  As will be appreciated by those skilled in the art, different heat sources can be combined and used in the radiation chamber. In addition, multiple chambers may be used sequentially to prevent the casting from cooling to a temperature substantially above or above the process control temperature and thereafter maintain the casting temperature until the casting enters the heat treatment station. it can.

In another aspect, the off-gas which is generated when injecting thaw metal, as indicated by arrow 60, is guided to the radiation chamber of the process temperature control station 36, the thermal energy from the heating of the shared and casting metals May allow recovery. In yet another aspect, the excess heat generated as a result of the decomposition and combustion of the casting sand core and / or sand mold binder in the heat treatment station 42 and the heat treatment of the casting is indicated by the dotted arrow 61 in FIG. 1A. As such, it can be returned to the process temperature control station to assist in heating the internal environment of the radiation chamber of the process temperature control station. Such recapture of waste gas and heat helps to reduce the amount of energy required to heat the chamber of the process temperature control station to the desired or required temperature and prevent cooling of the castings therethrough. .

  As additionally shown in FIGS. 2B, 4A, 5A, and 6A, a collection hopper or chute 62 is positioned along the bottom of the process temperature control station 36 below its radiation chamber 37. May be formed. The hopper 62 generally includes a side wall 63, and a lower end 64 of the side wall 63 is inclined downward. The sloped sidewall collects the sand that has detached from the casting sand core and / or sand mold as the binder begins to thermally degrade in the process temperature control station. The sand is typically directed downward toward a collection conveyor 66 located below the open lower end of the hopper 62. Typically, a fluidization system or mechanism 67 is positioned along the lower portion 64 of the hopper 62 wall. Fleurizers are typically disclosed and claimed in US Pat. Nos. 5,294,994, 5,565,046, and 5,738,162, incorporated herein by reference. Including a burner, blower, distributor, or similar fluidizing unit. These fluidization units add a flow of heat medium, eg air or other fluid, to the sand to promote further degradation of the binder and to break up the sand and binder agglomerates that have detached from the casting. Helping to regenerate the cast sand core and / or sand mold sand in a substantially pure form. The reclaimed sand is collected on a conveyor 66 and conveyed from a process temperature control station.

  Further, as shown in FIGS. 1A, 2A, 2B, 4A, 5A, and 6A, excess heat and waste generated by the combustion of a casting sand core and / or a sand-type binder material. The gas can be collected or drawn out of the radiant chamber 37 of the process temperature control station 36 and directed to the heat treatment station 42 as indicated by arrow 68 in FIG. 1A. This channeling of excess heat and waste gas from the process temperature control station to the heat treatment station is a potential recovery of the heat generated in the chamber of the process temperature control station and the sand mold and / or core in the heat treatment chamber. Allows further heating and / or combustion of the waste gas resulting from the deterioration of the binder. As shown in FIG. 1A, a blower or similar air distribution mechanism 69 is also typically installed along the heat treatment station, typically waste gas generated during the heat treatment of the casting, and the casting. The resulting burn-off of the binder material from the sand core and / or sand mold. These waste gases are collected by a blower and are typically directed to an incinerator 71. The incinerator 71 further processes and incinerate these waste gases to rework these gases to reduce the amount of contaminants produced by the casting and heat treatment processes. In addition, a filter can be used to filter the waste gas coming from the process temperature control station before it is introduced into the heat treatment station and / or to filter the gas coming from the heat treatment station to the incinerator.

  The process temperature control station consequently functions as a hotbed area in front of the heat treatment station or chamber where the casting can be maintained. In that hotbed area, while waiting for the casting to be introduced into the heat treatment station, the temperature of the casting is such that it is at or above the process control temperature, but below the desired heat treatment temperature. Maintained or prevented. Thus, the system allows the casting line to operate at a faster and more efficient rate and is left in a queue or queue waiting for the casting to be sent to the heat treatment station, during which it is exposed to ambient temperature. Thus, it is not cooled below the process control temperature. Thereafter, the castings are sent to the heat treatment station 42 individually as shown in FIGS. 1A, 1C, 2A, and 2B or as a lot as shown in FIGS. 1B, 1C, and 3. Heat treatment, sand core and / or sand mold decomposition and removal, and in some cases, sand regeneration.

  The heat treatment station 42 (FIG. 2B) may be a long furnace. A long furnace includes one or more furnace chambers 75, which are attached sequentially. Conveyor 76 is extended through the furnace and transports the casting through it. A convective heat source, eg, a heat source 77 including a heat medium, eg, a blower or nozzle applying air or other fluid, a conduction heat source, eg, a fluidized bed, induction, radiation, and / or other types of heat sources (FIG. 2A ) May be mounted in the walls and / or ceiling of chamber 75 to provide heating and optional air flow around the casting in variable steps and amounts to heat the casting to the proper heat treatment temperature. Such desired heat treatment temperature and heat treatment time will vary according to the type of metal or metal alloy from which the casting is formed, as is known to those skilled in the art.

  Examples of various heat treatment furnaces suitable for use with the present invention are described in US Pat. Nos. 5,294,994, 5,565,046, and 5,738,162. The disclosures of these patents are incorporated herein by reference. Additional examples of heat treatment furnaces or stations used with the present invention are described in US Pat. No. 6,217,317, US patent application Ser. No. 09 / 665,354 filed Sep. 9, 2000, and 2002. Illustrated and disclosed in US Ser. No. 10 / 051,666, filed Jan. 18. These disclosures are also incorporated herein by reference in their entirety. Such a heat treatment station or furnace may include features for reclaiming sand from cores and / or molds that have detached during heat treatment of the casting.

  After heat treatment, the casting is typically removed from the heat treatment station and moved to a quenching station 78 (FIG. 1A) for post processing and further processing. A quenching station typically includes a quench tank having a cooling fluid, e.g., water or other known refrigerant, and has a series of nozzles that apply a cooling fluid, e.g., air, water, or similar refrigerant. A chamber can be included. Thereafter, the casting may be removed for further post-processing and processing as needed.

  Another exemplary integration facility 5 is shown in FIG. 1B. The equipment 5 includes a transfer mechanism 27 shown as a crane or robot arm 28. The transfer mechanism 27 removes the casting from the plurality of casting lines or stations 11 and 11 '. In this example, the casting line or stations 11 and 11 ′ are shown as a carousel type system and the mold rotates between the pouring or casting position 23 and the transfer point 24. The transfer mechanism 27 engages and transports the sand mold containing the casting, or removes the casting from the mold and transfers the casting to one or more inlet conveyors 34 and 34 ′ of the heat treatment unit 26. The castings may be individually moved to the process temperature control station 36 and introduced into the heat treatment station 42 or collected in a basket or transfer tray 79 and processed in lots.

  In the exemplary system 5 shown in FIG. 1B, the process temperature control station 36 is generally formed as a long radiant tunnel 81. Tunnel 81 defines a chamber 82, and castings and / or casting-containing sand molds are moved or transported through chamber 82. The radiant tunnel 81 includes a series of heat sources 83 mounted along it, such as the various heat sources 45, 45 ′, and 45 ″ previously described with respect to the embodiments of FIGS. 2A, 2B, and 4A-6B. Typically, the walls 84 and ceiling of the chamber 82 of the radiant tunnel 81 are formed or coated from a refractory material, and the heat generated in the radiant tunnel is reflected and / or radiated towards the casting. Castings may be collected and / or deposited in the basket 79 or similar transport tray of the collection station 86 at the end of the radiant tunnel 81. Such baskets 79 or trays contain castings and / or molds. It may be used to pass through the heat treatment station 42. The casting is alternatively collected in a basket, as shown in FIGS. , Before casting passes through the radiation chamber or tunnel the process temperature control station 36, may be processed as a lot in the heat treatment station.

Yet another exemplary integration facility 5 in accordance with the present invention is shown schematically in FIG. 1C. In this embodiment, the process temperature control station 36, shown as a long radiant tunnel or chamber 81 (described with respect to FIG. 1B), connects or flows into the chill removal station 87. The chill removal station 87 communicates with the heat treatment station 42 and feeds the casting. Typically, the casting is moved and heat treated or processed while contained in a semi-permanent mold or sand mold. The semi-permanent mold or sand mold is further fitted with a “chill”. Chill is typically a metal plate, typically formed from steel or similar material, has a design relief that forms a desired design features of the surface of the casting, during injection of the thaw metal material Or put in the mold before injection. Accordingly, the chill must be removed prior to heat treatment of the casting or chill regeneration and reuse. After passing through the chamber 82 of the radiant tunnel 81 where sand burning generally begins at least partially, the chill can be easily removed and significantly delays the movement of the mold and casting to the heat treatment station 42. Absent. Following removal of the chill at the chill removal station, the mold containing the casting is typically passed directly to the heat treatment station for heat treatment, sand core and sand mold decomposition, and sand regeneration.

  FIG. 1D shows yet another exemplary installation according to the present invention. In this embodiment, the casting is typically removed from the mold and transported to the inlet conveyor 90 or 91 and fed directly to one or more heat treatment furnaces or stations 92. Alternatively, if the casting is formed in a sand mold, the entire mold is transported from transfer point 28 to one of inlet conveyors 90 or 91. As shown in FIG. 1D, removal of the casting from the mold and subsequent transfer of the casting, or removal of the casting mold from the casting station and transport to the heat treatment station 92 is generally the same transport mechanism. Or it can be done by a manipulator.

  In this embodiment, the heat source 93 is attached to the transfer mechanism 27 and applies heat directly to the casting and / or sand mold as the casting is moved from the casting line transfer point to one of the inlet conveyors 90 or 91 of the heat treatment furnace 92. . As described above, the heat source may include a radiant energy source, such as an infrared or electromagnetic emitter, an inductive, convective and / or conductive heat source, or other types of heat sources apparent to those skilled in the art. Heat from a heat source 93 attached to the transfer mechanism 27 is directed to one or more surfaces, such as the top and / or sides of the casting or mold, as the casting or mold is transferred to the inlet conveyor. And / or prevent mold cooling, thereby maintaining the temperature of the cast metal substantially at or above the process control temperature of the metal.

  An additional heat source 94 is mounted on or adjacent to the inlet conveyors 90 and 91 as shown in FIG. 1D, or in the transfer mechanism travel path as shown by arrows 96, 96 ′, 97, and 97 ′. Can be attached along and can maintain the temperature of the casting. In addition, a blower, fan, or similar air moving device (not shown) is placed adjacent to the transfer mechanism or along its moving passages 96, 96 ′, 97, and 97 ′, For example, air or other thermal fluid can be applied to the transfer mechanism. The blower distributes the heat applied to the casting and / or mold and minimizes uneven heating or cooling of the casting while the casting is transferred from the casting line to the heat treatment furnace 92. Thus, the use of such a heat source or element mounted on the transfer mechanism or in some arrangements along the casting movement path performs the function of the process temperature control station and prevents cooling. Helps maintain the casting at substantially the process control temperature or above.

  Yet another aspect of the present invention is shown in FIG. In this example, the castings and / or sand molds are placed directly into the collection basket or transport tray 100 by the transfer mechanism 27 and fed to the process temperature control station for the lot heating process. In such an arrangement, the casting 12 is typically loaded into a series of partitions or chambers 101 in the transport tray 100. The casting was filed on September 9, 2000, and as disclosed and claimed in US patent application Ser. No. 09 / 665,354, which is incorporated herein by reference in its entirety, to a known indexing position. As the casting is moved and passed to the process temperature control station 102 and the heat treatment station 103, directed heat is applied to remove the core and perform other functions. In this embodiment, the tray 100 typically splits into or out of the process temperature control station chamber 104 as indicated by arrows 106 and 106 'as the casting is loaded therein. Is issued. As a result, the exposure of the casting to the ambient environment that cools the casting below the process control or critical temperature is minimized while the various other partitions 101 of the tray are loaded with the remaining casting of the lot.

  Further, as shown in FIG. 3, it is possible to provide a heat source 107 directed to each of the partitions 101 of the tray 100. For example, when the first partition 101 ′ is loaded with a casting 12 ′ and indexed into the process temperature control station 102, the first heat source 107 ′ may be of the casting and / or sand mold in that particular chamber. Towards the heat towards. Thereafter, when successive castings or molds are loaded into other chambers or partitions of the basket, additional heat sources 107 directed to those partitions are engaged. Thus, the heating of the process temperature control station chamber 104 can be limited or directed to specific areas or zones as needed, and the casting is heated more efficiently.

  As further shown in FIG. 3, a series of blowers or other similar air moving devices 108 are attached to the roof of the process temperature control station and are generated by the degradation of sand cores and / or sand-type binder materials. Gas can be discharged. Gas and additional waste heat may be directed to heat treatment station 103 via conduit 109 to regenerate heat and reduce contaminants, with combustible waste on the side and ceiling of the process temperature control station 102 chamber. Helps prevent being collected.

  Thus, in light of the above detailed description of the invention, it will be readily appreciated by those skilled in the art that the invention has broad utility and applicability. Many adaptations of the invention other than those described herein, and many variations, modifications, and equivalent arrangements will be apparent from or reasonably suggested to the invention and the above detailed description, They will not depart from the spirit or scope of the present invention.

  Although the invention has been described in detail herein with reference to specific aspects, this detailed description is only illustrative and exemplary of the invention and is merely intended to provide a complete and authoritative disclosure of the invention. You should understand what was done in The detailed description set forth herein is not intended, and is not intended to limit the invention or to exclude other such embodiments, adaptations, variations, modifications, and equivalent arrangements of the invention. Should not be interpreted. The present invention is limited only by the claims appended hereto and their equivalents.

Claims (14)

A method of forming a casting having a reduced heat treatment time, comprising:
A process of casting molten metal into a mold to form a casting,
Monitoring the temperature of the casting,
Comparing the temperature of the casting with a predetermined process control temperature, wherein the process control temperature is below that temperature every minute of the time the casting temperature decreases. A temperature at which a heat treatment of more than 1 minute is required to obtain the desired properties of the casting,
Applying heat to the casting if the temperature of the casting is lower than the process control temperature;
Placing the casting in a heat treatment furnace, and heat treating the casting. Applying the heat to the casting allows sufficient heat to be applied to the casting to allow the molten metal to solidify while maintaining the temperature of the casting at or above the process control temperature. The method of claim 1 comprising: A method of forming and heat treating a casting,
A process of casting molten metal into a mold to form a casting,
Monitoring the temperature of the casting,
Comparing the temperature of the casting with a predefined rejection temperature and rejecting the casting if the temperature is less than or equal to the rejection temperature;
Comparing the temperature of the casting with a predetermined process control temperature and, if the temperature is higher than the rejection temperature but lower than the process control temperature, applying heat to the casting, and heat treating the casting Including steps,
Here, if the process control temperature is lower than that temperature, a heat treatment exceeding 1 minute is required every 1 minute during which the temperature of the casting is lowered in order to obtain the desired properties of the casting. Temperature
Method. The method of claim 3, wherein the rejection temperature is 10 ° C. to 20 ° C. below a process control temperature of the casting metal. The method of claim 3, wherein the rejection temperature is 10 ° C. to 20 ° C. below the temperature of the heat treatment furnace. A method of forming and heat treating a casting,
Pre-determining a process control temperature for the metal of the casting, wherein the process control temperature is less than that temperature every minute of the time the casting temperature decreases, A temperature at which a heat treatment of more than 1 minute is required to obtain the properties of
Predefining a rejection temperature below the predetermined process control temperature for the metal of the casting;
Injecting molten metal into a mold at an injection station to form a casting;
Transferring the casting from the pouring station to a heat treatment furnace along a path of movement and fully solidifying the molten metal in the mold to form the casting;
As the casting is moved from the injection station to the heat treatment furnace along the path of movement, at least one temperature detector along the path of movement, periodically or at determined intervals. Automatically monitoring the temperature of the casting;
Comparing the monitored temperature of the casting with the predetermined process control temperature and in response to the comparison of the monitored temperature with the predetermined process control temperature; (i) 1 One or more heat sources are controlled along the path of movement of the casting from the injection station to the heat treatment station, and (ii) the controlled if the temperature of the casting is lower than the process control temperature. Applying heat from a heat source to the casting;
Passing the casting through a rejection area defined prior to entering the heat treatment furnace;
Monitoring the temperature of the casting with at least one temperature detector when the casting is in the rejection area to determine a rejection area temperature of the casting;
Comparing the monitored rejection region temperature of the casting with the predefined rejection temperature, and in response to comparing the monitored rejection region temperature with the predefined rejection temperature Rejecting the casting if the temperature is less than or equal to the rejection temperature; and, if not, rejecting the casting in the heat treatment furnace. The rejection temperature is below only 1 0 ℃ ~ 2 0 ℃ than the process control temperature for the metal of the casting method according to claim 6. The rejection temperature is lower by 1 0 ℃ ~ 2 0 ℃ than the temperature of the heat treatment furnace, method of claim 6.   Applying the heat to the casting allows sufficient heat to be applied to the casting to allow the molten metal to solidify while maintaining the temperature of the casting at or above the process control temperature. The method of claim 6 comprising: An integrated system for forming and heat treating a metal casting, the system comprising:
An injection station for injecting molten metal into a mold to form a casting;
A heat treatment station downstream from the pouring station for receiving and heat treating the casting;
A process control temperature station located upstream from the heat treatment station;
A rejection area that is part of or separate from the process control temperature station; and a transfer mechanism for transferring castings between the injection station and the heat treatment station, comprising: A transfer mechanism communicates with the control system of the rejection area, and when the control system detects that the temperature of the casting is equal to or below the predefined rejection temperature; A transfer mechanism configured to remove the casting before the casting enters the heat treatment station;
Here, the process temperature control station is
Between the pouring station and the heat treatment station, it is disposed along a path of casting movement, and heat is applied to the casting as needed to allow the casting to move from the pouring station along the path of movement. A series of heat sources to maintain the casting as a predetermined process control temperature or higher for the metal of the casting as it is moved to a heat treatment station;
At least one temperature sensing device, (i) either continuously or periodically at determined intervals as the casting is transferred from the injection station to the heat treatment station along the path of movement And (ii) at least one temperature detection device arranged to monitor the temperature of the casting and in communication with the series of heat sources; and the at least one temperature detection apparatus and the series of A controller in communication with a heat source, wherein the controller causes the casting by the series of heat sources to maintain the temperature of the casting at or above the process control temperature for the metal of the casting prior to heat treatment. The amount of heat applied to the casting, wherein the process control temperature is below the heat treatment temperature for the metal of the casting so that the casting is sufficiently Cooled to such an extent that the casting can be solidified, but below that temperature, to obtain the desired properties of the casting every minute of the time when the temperature of the casting decreases. It is equipped with a controller at a temperature that requires heat treatment time exceeding 1 minute,
Here, the rejection area is
At least one temperature detection device arranged to monitor the temperature of the casting in the rejection area, the at least one temperature detection device being the at least one temperature detection device of the process control temperature station or a separate one. At least one temperature detector, and a control system that is either the controller of the process control temperature station or a separate control system, the control system comprising: In communication with the at least one temperature sensing device in the rejection region, the control system is configured to cause a casting temperature in the rejection region to be lower than a predefined rejection temperature lower than the process control temperature of the casting metal. A control system configured to determine when low;
Comprising
Integrated system.   11. The system of claim 10, wherein the heat source is sufficient to inhibit cooling of the casting without heating the casting above the heat treatment temperature required for the casting metal. A system for applying heat to the casting. 11. The system according to claim 10, wherein the process control temperature is less than that temperature, at each minute of time during which the temperature of the casting decreases, and the desired characteristics of the casting are determined. A system that is at a temperature that requires at least 4 minutes of heat treatment to acquire.   The system of claim 10, wherein the metal is an aluminum / copper alloy and the process control temperature is between 400 ° C. and 470 ° C.   The system of claim 10, wherein the metal is an iron alloy and the process control temperature is between 1000 ° C. and 1300 ° C.