US2338153A - Foundry plant - Google Patents

Description

Jan 4, 1944. E wHlTTAKER 2,338,153

FOUNDRY PLANT Filed July 9, 1941 6 Sheets-Sheet 1 l I ATTORNEYS.

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E. H. WHITTAKER FOUNDRY PLANT Jan. 4, 1944,

Filed July 9; 1941 5 Sheets Sheet 5 I INVENTOR. Edwar d H.Whi11ak 51" Z2 Z5 I I ATTORNEYS.

Patented Jan. 4, .1944

UNITED STATES PATENT OFFICE roUNDRYr-LANT Edward H. Whittaker, Jersey City, N. J. Application July 9, 1941, Serial No. 401,651 12 Claims. (01. 2264) While it is broadly old to provide so-called continuous foundry plants or systems, such have, in the past, been mainly designed to permit economical production of specialized castings, such as pipes or car wheels. The present invention has for one of its objects to provide a foundry plant having the economies resulting from increased production, specialization of labor, reduction of floor space, etc, but which will also enable the workmen to produce a large variety of castings. This is in part accomplished by the provision of a workmans car which may be moved to any one of many pouring stations located from one end of the plant to the other end thereof, transferring the hoists for pouring accessories, as well as the specialized workmen to various foundry units, each comprising related molding, cupola, pouring and shake-out stations. Thus flasks may be filled and rammed and the molds properly dried at one molding station and the metal conditioned at its related cupola station, while the workmans car and the specialized crew are at some other foundry unit, using the molds and hot metal previously conditioned there for casting.

Another object of the invention is to provide an improved foundry plant where the molds and their'accessories are moved about the workmans car with a minimum amount of power and efiort and which will tend to overcome the tendency of workmen to get in the way of one another,

thereby reducing the likelihood of accidents to a minimum, and tending to speed up production to a maximum.

Another object of the invention is to provide a workmans car equipped to expeditiously and without tiresome labor on the part of workmen, to deliver to and remove from the molds suitable weights used during the pouring operation. By thisarrangement the same weight maybe used many times on difierent molds during the period that the workmans car is active at any particular foundry unit, thus reducing the number of weights required and conserving space.

A further object of the invention is to provide a workmans car equipped to permit transportation of hot metal, for the pouring of the molds,

conveniently and with comparative safety, and so the hot metal will not cool to any appreciable extent during the time it leaves the cupola to the time it ultimately finds its way into the molds. Another object of the invention is to provide a workmans car which may be moved together with a crew of workmen from one foundry unit to another and which may be adjusted to ride over areas where molds are cooling or where other work is in progress and yet provide a comparatively unobstructed workmans area when the car is at rest for the pouring operation.

Other objects and advantages of the. invention will appear in the following detailed description, taken in connection with the accompanying'drawings, forming a part of this specification, and in which draw1ngs-- Figure 1 is a view in elevation, partly in section, but'generally diagrammatic, of substantially ing parts in proper relative position for conditioning the metal for the pouring operation and for storing castings or poured molds while coolmg.

Figure 3 is a diagrammatic plan view of a portion of a foundry plant showing a plurality of side by side foundry units and a central zone in which the workmans car may move from one unit to another as molds are ready for the pouring operation.

Figure 4 is a view partly in elevation and partly in section longitudinally of a workmans car in the zone wherein the car may be moved from one foundry unit to another.

Figure 5 is a similar view transversely of the car and the zonein which it is movable.

Figure 6 is a view partly in plan and partly in horizontal section of a power driven roller bed which may be used to reduce labor in moving hot metal from a cupola station to a pouring station.

Figure 7 is a view partly in elevation and partly in vertical section on substantially the line of Figure 6.

In the preferred embodiment of the invention, the various working parts are disposed in a building, the main floor level of which is substantially in the plane of the line AA, Figures 1 and 2, so that the flasks, molds, castings, and accessories'may be moved about, to a great extent, without the use of hoists and overhead cranes, but rather by workmen pushing same over roller beds forming a part of the floor or guiding supplies, etc., over power driven roller beds forming a part of the floor, in order to transfer equipment and products from station to station.

The foundry plant preferably comprises a plurality of side by side foundry units B as indicated in Figure 3. These units B may each be likened to a foundry in itself, having all the facilities of a foundry with the exception that the units B are traversed by a zone C in which a mobile workmans car D may be moved from one unit to another unit whenever molds and hot metal in any particular unit are ready for the pouring step. While each unit B may be equipped to make the same or substantially the same castings, the foundry plant is particularly well adapted to make a large variety of castings. In that way the plant may be used to make all of the necessary castings for a given job, such as a machine or engine, and skilled labor for making molds and conditioning metal for pouring a particular part or parts may be stationed at a particular unit designated for the production of such parts, while the skilled labor for pouring the hot metal at times travel from unit to unit, remaining at any particular unit only long enough to complete the pouring step in the process of making the castings. In that way work is carried on without loss of time and workmen are not likely to get in the way of one another. Skilled workmen may also be engaged in preparing molds, breaking up molds, cleaning flasks,

conditioning metal for casting, and allowing flasks to remain in storage until properly dried at one or more of the units B, while the workmans car D is located at another foundry unit for the pouring of molds which are in condition to receive the hot metal. It is of course understood that a foundry plant may be provided with more than one workmans car if the plant is so large that one would not suffice.

In the example shown, the units B are also traversed by a way E for bringing supplies to the units, such as sand, cores, etc., and for removing refuse from the vicinity of the units B. Likewise I prefer to provide overhead ways F traversing the units B for bringing supplies of ore, chemicals, fuel, etc., for the making of casting metal, and underground ways G also traversing units B, for removing waste products of combustion, slag, etc., as shown in Figures 1, 2 and 3, this being quite common practice in connection with batteries of cupolas.

Each unit B comprises a molding station H; a mold storage and conditioning station J; a mold pouring station K located in zone C; a cupola station L; a casting storage station M; and a shake-out and sand conditioning station N.

Also each unit B includes a sand bin 0 beneath way E; an endless conveyor P, for sand, of rectangular form movable in a vertical plane and traversing beneath bin 0 and stations J and N and'over way E and stations J and N; a sand valve Q and chute R in way E; a roller bed S paralleling stations H, M and N; a roller bed T at station N; several roller beds U paralleling each other and station H, located at station J; several roller beds V paralleling each other, located at station K and aligned with roller beds U; a mechanically operated roller bed W paralleling station L and aligned with one of the roller beds V; overhead crane X for servicing station H; and, overhead crane Y for servicing stations H and J.

There are also provided two or more overhead cranes Z movable in zone C for moving car D and servicing stations K and N of many foundry units B.

For supplying molten metal from the cupola station L to the workmans car D, there is provided suitable hot metal transporting and pouring equipment I a typical example of which is shown more in detail in my copending application for patent filed May 20, 1942, Serial No. 443,795.

At molding station H may be located any number of flask charging and molding machines 20, of any suitable type, and at cupola station L may be located any number of cupolas 2|.

' The endless conveyor P in the example shown,

comprises buckets 22 carried by chains 23, trained about sprocket wheels 24, any pair of which may be driven by a suitable motor, not shown in the drawings, so as to provide a lower run 25, an ascending run 26, an upper run 21, and a descending run 28 of the conveyor; and lower and upper housings 29 and 30' for the runs 25 and 21, respectively. The housing 30 has a. grill 3| providing openings 32 over the machines 20 and an opening 33 to the sand valve Q, while the housing 29 communicates with the bottom of bin 0 as at 34 and with equipment located at station N.

In Figure 1 is shown a car 36 located in way E which may be used to bring new sand to bin 0 or receive sand, unfit for further use in making molds, thru valve Q and chute R, in order that it may be carriedaway from the foundry. Cars in way E may also be used to bring supplies to stations H and J and to carry trash therefrom.

The cranes Z may each be any suitable of overhead traveling crane with motive power, operators cab, hoist, etc., not shown in the drawings. In the drawings it is shown equipped with a coupler part 31 for cooperation with a companion coupler part 38 on the workmans car D. One function of crane Z is to lift flasks with molds from station K to station N, and empty flasks from station N to roller bed S.

The roller beds S, T, U and V are preferably of the free roller type in contradistinction to roller bed W which is preferably mechanically driven. Since the beds having rollers free to rotate in either direction may be substantially the same, it suifices to describe the construction shown in Figures 4 and 5 where the rollers 41 have'shafts 48 rotatable in bearings carried by standards 49 mounted on a sub-floor 50, there being stationary floor panels 5| between the upper portions of the rollers and stationary floor strips 52 laterally of the rollers, these panels and strips preferably being of the grating type so dirt may fall to the sub-floor 50 and give good foot hold to workmen. The panels and strips may be supported by the standards 49 in any suitable manner. Large stationary floor panels 53 may surround the machines 20, and large stationary floor panels 54 may constitute the major floor area of station N, as shown in Figure 3. Stations L and M may have solid floors 55 and 56 like those usually surrounding the bases of cupolas and for supporting castings in storage. Otherwise a substantial portion of the floor area of each foundry unit B, not

cupied by machines, may be said to constitute roller beds to facilitate movement of flasks, molds, castings, etc., thereover with little use of hoists or cranes.

The roller bed W is particularly well adapted to facilitate movement of part of the equipment I from the cupola station L to the pouring station'K, in a safe manner. -It comprises a plurality of parallel rollers 51, keyed to shafts 58 supported by bearings 59 on beams 60. 'Motion may be transmitted to one of the shafts 58 by motor 6| and gearing comprising a pinion 62 on the motor shaft, meshing with gear 63 on said roller shaft. Motion may be transmitted to all of the rollers 58 of bed W by sprocket wheels 64 and 65 on shafts 58, and endless chains 66 and 61 trained about these wheels 64 and 65 in the well known manner.

Inasmuch as it is desired to provide equipment with a minimum of accessories, I prefer to provide flasks 39, the drag section 68 and cope section 69 of which are held together during the pouring operation by a weight 10 which may be used over and over again during the pouring period. The weight functions to hold the drag and cope firmly together only as long as necessary for the pouring of the mold and reduction in temperature of the hot metal to a point where it ceases to flow. In this way I may avoid the use of clamps, bands, or jackets for the flask parts. In Figures 4 and I show an example of the preferred equipment. The drag 68 is shown resting upon a bottom board 1| which facilitates movement of the mold oven-the-various roller beds at.stations J and K. In my 60- pending application for patent on flasks and weight means therefor, filed September 9, 1942, Serial No. 457,763, I havedisclosed and claimed characteristics of the flasks and weight means shown in Figures 4 and 5.

The weight is provided with sprue holes 89, as shown in Figure 5,. to align with gates, not shown in the drawings, thru which hot metal may flow into the mold.

As diagrammatically indicated in Figure 1, i is preferred to provide at least two flask charging and molding machines at each molding station H-one for making the mold in the drag and the other formaking the mold in the cope.

'Ihe flask and mold conveying mechanisms X and Y movable on tracks 239, maybe of any suitable type and an example of such is shown in my copending application for patent on conveying.

mechanisms for foundry plants, filed September 9, 1942, Serial No. 457,764. The mechanism X is particularly intended to move empty flasks to machine 20 and'mechanism Y to remove the flasks and molds'from the machine; to assist in pairing them; and to move the paired molds to suitable positions in the station J, in readiness to move them to the pouring station K after they are sufficiently dry and otherwise conditioned for the pouring operation.

' The workmens car D is in the nature of a combined overhead traveling crane and crew car, movable in the zone C from one foundry unit B to another of such units, as molds and hot metal are ready for the pouring operation. The car D in the example shown comprises an upper frame 286 supported by wheels 281 on overhead rails 288 which in turn are supported bycolumns 289; a lower frame 290 adjustably suspended from frame 286 by hangers 291'; a pinrality of outer trolleys 292 suspended from and movable aboutan outer continuous cycle track 293 supported by and located beneath frame 286 and preferably driven mechanically as by means 294, each trolley pendently supporting a hoist 295 preferably equipped with a hook 296; a plurality of intermediate trolleys 291, suspended from and movable about an intermediate continuous cycle track 298 supported by and located beneath frame 286 and inwardly of track 293, each trolley 291 pendently supporting a hoist 299, also preferably equipped with a hook.

300; a plurality of inner trolleys 30! suspended from and movable about an inner continuous cycle track 302 likewise supported by and located beneath frame 286 inwardly of track 293, each trolley 301 pendently supporting a hoist 303, likewise preferably equipped with a hook 304; and a platform or cat-walk 305 for workmen, secured to lower frame 290.

The upper frame 286, in the example shown, comprises side members 306, end members 301 and intermediate brace members 308. The side members 306have the wheels 281 rotatably secured thereto and the end members 301 centrally of their length may each carry the coupling member 38 previously described for cooperation with the companion coupling member 31 on power driven cranes Z, also movable on rails 288, as shown in Figure 3.

While the workmens'car may support means for moving it along the track formed by rails 288, it is preferred to move this car for transportation of workmen by means of the cranes Z since the latter are useful in transporting poured molds, flasks, castings, etc., along zone C while the car D is in use at another pouring station.

The hangers 29l may be of any suitable construction and in the example shown each comprise a tubular member 309 secured to and depending from frame 286; a column 3l0 secured to the frame 290 telescoping in each member 309 and provided with a plurality of transverse openings 3H; and one or more transverse bars 2 removably'carried by member 309 and adapted to be extended thru a selected opening 3, according to the distance it is desired to support the frame 290 above the floor A-A. The

, hangers 29l are preferably located at the corners 'may be many on track 293; sprocket wheels 3l5 rotatably carried by track 293; and motion transmitting means 3I6 between motor 3l3 and any one of the sprockets ("5. Thus the trolleys 292 and their hoists 295 may be moved continuously about the zones in which the trolleys 291 and 301 move, for the hoists 295 are primarily intended'to handle the weights 10 of which one is shown in Figure 10, for placing them on the molds as they enter the pouring station K from the storage and conditioning station J, or to remove them from the molds after the pouring step, so as tov permit their re-use many times during the period while the car D is in use at a particular foundry unit B. It is preferred not to drive the trolleys 291 and 30I mechanically. They may travel about their respective tracks by workmen exerting a pulling or pushingforce on some of the equipment carried by these trolleys. The trolleys and hoists may be of any suitable or preferred construction so they are more or less diagrammatically illustrated in the drawings.

The platform or cat-walk" 305 preferably extends only along the lower frame 290, leaving a largeopen space 3I'l, shown in Figure 3, in which the pourers and other workmen may move during the pouring operation. When such is completed, upon sounding or flashing of suitable signal, the workmen may mount the platform 305 and the entire crew may be moved to another foundry unit B by either crane Z pulling or pushing the car D.

The coupling members 30 shown in Figure3 may be of any suitable type, such as those used to connect railway cars and may be equipped with links, levers, etc., not shown in the drawings, so they may be rendered operable for coupling or uncoupling by workmen standing on'the main floor, on the platform 305, or from suitable motormens cabs, not shown in the drawings, carried in the usual way by traveling cranes.

Referring now to the combined shake-out and sand reconditioning or retempering apparatus at station N, it includes the spaced roller bed T and a typical example of such apparatus is shown in my copending application for patent, filed October 24, 1942, Serial No. 463,231.

As may be noted in Figure 3, the roller bed T extends above and laterally, as at 322, to each side of the space occupied by suitable apparatus 32! for conditioning the used sand shaken'from the flask, for reuse, there being the rigid floor panels between rollers 41, but rollers 41' directly above apparatus 32! are spaced and have no intervening panels so that sand, broken castings, trash, etc., may fall downwardly between the rollers 41. It is on these laterally'extending portions 322 that grilles with castings thereon may be moved in readiness to be transported by crane Z to roller bed S, to make room for another flask, mold and casting, to be separated at this station. Or, either laterally extending portion 322 of the roller bed T may receive defective flasks not in condition for re-use without repair.

The hot metal transporting and pouring equipment I shown in Figures 4 and 5, is particularly intended to promote safety and avoid delay by rendering the parts operative notwith standing the tendency of parts to stick as a result of reduction of temperature of the metal while being transported from the cupola to the pouring station. Broadly speaking the equipment comprises a valve controlled bucket 383; a detachable bail or coupling 384 for use with hoists 299 and 303 at the workmens car D; arid a safety-handle means 385 whereby workmen may, with comparative safety, move the buckets about the workmens car, by means of the trolleys 291 and l, and hold them in the desired position for pouring.

The preferred valve controlled bucket is disclosed in detail and claimed in my copending ap plication for patent on hot metal ladles, filed May 20, 1942, Serial No. 443,795.

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from station'to station in a circuitous path.

Leaving station H, as by cranes Y, they are paired at station J and paired flasks accumulated 0n the roller beds U where the molds are allowed to dry sufficiently for the casting steps. They are mounted on bottom boards or plates H and may be readily pushed by workmen beneath the workmens car D when it is in that particular foundry unit, by travel on roller beds U and V. As any mold approaches the pouring zone, one of the weights 10 is lowered upon the cope from one of the trolleys 292 and its hoist 295. The mold thus weighted is pushed into the pouring zone at station K where a pourer uses equipment I to fill the mold. Thus filled,- the mold is pushed toward, but not into station N. At this point, the weight 10 is removed by use 'of an empty hoist 295, on one of the mechanically operated trolleys 292.

When all molds are poured and the weights removed, either crane Z is used to pull or push the workmens car D to another foundry unit, the crew which previously placed and removed the weights and poured the metal, mounting the platform or "catwalk" 305, so as to ride with the car.

During the pouring step, hot metal from the and pushed or pulled by means 385.

After the metal in the molds had hardened sufficiently to permit removal of the castings from the molds, they are moved by either crane Z, one by one, to the shake-out station N, and the empty flasks are returned to the molding station H on roller bed S. At the molding station, the flasks are placed in the machines 20 by use of cranes X, and the cycle of operation again commences.

The castings may be transported to either station M by use of crane Z and roller bed W which parallels station M, or in any desired manner, one of the most important features of the foundry plant, being the plurality of side by side foundry units B with a zone C common to all, in which car D may move from one unit to another, as the molds and metal are ready for easting. The car D is so constructed and arranged that workmen are not likely to get in the way of one another; that unskilled labor may be used to place and remove the weights 10 without loss of time or interference with the pourers; that the pourers will have a more definite zone in which to work and act quickly to complete the pouring operation; that the car may not only transport the hoisting equipment, but also the entire crew to a different foundry unit with little,

' if any, loss of time; and that the lower frame of the car may be hoisted to clear material or workmen in zone C as it travels from unit to unit.

In the drawings many structural details have been omitted since they are all well known in the art and may be provided for safety purposes, to reduce friction and to add to the comfort and efficiency of the workmen. As to accessories, there is such a wide choice from which selection may be made, that some .have been shown only in a general way, since they too are well known in the art and there is a wide range of equivalents which might be used without departing from the spirit and scope of my invention. In

Figures 1, 2 and 3, practical proportions as to the pouring stations of all of said units; and a workmans car movable in said zone from unit to unit thereof, said car provided with means for conveying hot metal for casting about the pouring station atwhich the car is located and means for transporting the pouring crew from unit to unit, whereby molds and hot metal for casting may be prepared at one of said units while the pouring operation is being performed at another of said units.

2. A foundry plant comprising a plurality of foundry units in side by side relation, each unit including a molding station, a pouring station and a cupola station, with the pouring stations between the molding and cupola stations of their respective units, and with all of the pouring stations in alignment so as to provide a zone common to the pouring stations of all of said units; and a workmans carmovable in said zone from unit to unit thereof, said car provided with means for conveying hot metal for casting about the pouring station at which the car is located and means for transporting the pouring crew from unit to unit, whereby molds and hot metal for casting may be prepared at one of said, units while the pouring operation is being performed at another of said units.

3. A foundry plant comprising a plurality of foundry units in side by side relation, each unit including a molding station, a pouring station,

a shake-out station, and a cupola station, witha zone common to the pouring and shake-out stations of all of said foundry units; a workmans car movable in said zone, from unit to unit thereof, said car provided with means for conveying not metal for casting about the pouring station and means for transporting the pouring crew from unit to unit, whereby molds and hot metal for casting may be prepared at one unit while the pouring operation is being performed at another of said units; and a crane movable in said zone for moving said car and for transporting flasks and molds from said pouring station to said shake-out station.

4. A foundry plant comprising a plurality of continuous foundry units in side by side relation, each unit including a molding station, a mold storage station, a pouring station and a shakeout station arranged in circuitous fashion so that flasks may be moved from the molding station to the other of said stations in sequence 'and returned to the molding station, said foundry units arranged with all oftheir pouring stations in alignment to provide a zone common to the pouring stations of all of said units; and a workmans car movable in said zone from unit to unit thereof, said car provided with means for conveying hot metal for casting, about the pouring station at which the car is located and means for transporting the-pouring crew from unit to unit after the pouring, operation.

5. A foundry plant comprising a plurality of continuous foundry units in side by side relation,

each unit including a molding station, a mold storage station, a pouring station and a shakeout station arranged in circuitous fashion so that flasks may be moved from the molding station to the other of said stations in sequence and returned to the molding station, and a cupola station adjacent said pouring stations, said foundry units arranged with all of their pouring stations in alignment to provide a zone common to the pouring stations of all of said units; and a workmans 'car movable in said zone from unit to unit thereof. said car provided with means for conveying hot metal for casting about the pouring station at which the car is located and means for transporting the pouring crew from unit to unit after the pouring operation, whereby molds and hot metal for casting may be prepared at one of said units while the pouring operation is being performed at another of said units.

6. A foundry plant comprising a plurality of foundry units in side by side relation, each unit including a station at which molds may be poured and temporarily stored while the metal is cooling, said foundry units arranged with all of said stations in alignment to provide a zone common to all of said stations, an overhead traveling crane movable in said zone, a continuous cycle track supported by and beneath said crane, a plurality of trolleys movably supported by said track, and a hoist supported by each of said trolleys.

'7. A foundry plant comprising a plurality of foundry units in side by side relation, each unit including a station at which molds may be poured and temporarily stored while the metal is cooling, said foundry units arranged with all of said sta- .tions in alignment to provide a zone common to all of said stations, an overhead traveling crane movable in said zone, a continuous cycle track supported by and beneath said crane, a plurality of trolleys movably supported by said track,

hoists supported by each of said trolleys, a platform for workmen, and means suspending said platform from .said crane, said means vertically adjustable whereby the platform may be raised toward or lowered with respect to said crane so byworkmen at any particular station.

8. A foundry plant comprising aplurality of foundry units in side by siderelatlon, each unit including a pouring station, said foundry units arranged with all of said pouring stations in alignment to provide a zone common to all of said pouring stations, an overhead traveling crane movable in said zone, a plurality of continuous cycle tracks supported by said crane beneath the same, said tracks arranged one inwardly of ansaid pouring stations, an overhead traveling crane movable in said zone, .a plurality of continuous cycle tracks supported by said crane beneath the same, said tracks arranged one inwardly of another so as to provide at least inner and one outer track, a plurality of trolleys movably supported by each of said tracks, a hoist supported by each of said trolleys, and mechanical means for spacing the trolleys of one of said tracks and driving them about their respective tracks.

10. A foundry plant comprising a plurality of foundry units in side by side relation, each unit including a pouring station, said foundry units arranged with all of said pouring stations in alignment to provide a zone common to all of said pouring stations, an overhead traveling crane movable in said zone, a continuous cycle track supported by said crane beneath the same, a plurality of trolleys movably supported by said track, a hoist suspended by each of said trolleys, and mechanical means for spacing said trolleys and driving them about said track.

11. In a foundry plant, the combination of a molding station, a mold storage station to one side of said molding station, a plurality of roller I beds in said mold storage station, said beds paralleling said molding station, means for moving molds from said molding station to said roller beds, a pouring station at the end of said storage station, and a plurality of roller beds in said pouring station aligning with the roller beds in said storage station.

12. In a foundry plant, the combination of a molding station, a mold storage station to one side of said molding station, a plurality of roller beds in said mold storage station, said beds paralleling said molding station, means for moving molds from said molding station to said rollerbeds, a pouring station at the end of said storage station, a plurality of roller beds in said pouring station aligned with the roller beds in said storage station, a shake-out station to one side of said pouring station and aligned with said molding station, a roller bed paralleling said shake-out station and molding station to the side of the latter opposite the roller beds of said storage station, means for moving flasks, molds and castings from said pouring station to said shake-out station, and flasks from said shake-out station to said last mentioned roller bed, and means for moving flasks from said last mentioned roller bed to said molding station.

EDWARD H. WHITTAKER.

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