US2832109A - Assembly die casting apparatus - Google Patents

Assembly die casting apparatus Download PDF

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US2832109A
US2832109A US608607A US60860756A US2832109A US 2832109 A US2832109 A US 2832109A US 608607 A US608607 A US 608607A US 60860756 A US60860756 A US 60860756A US 2832109 A US2832109 A US 2832109A
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die
nozzle
carrier
gate
casting
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US608607A
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William F Fisher
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Fisher Gauge Works Ltd
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Fisher Gauge Works Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/02Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • B22D17/04Plunger machines

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  • This invention relates to die casting apparatus and more particularly to such apparatus of fully or semi-automatic character, intended primarily but not wholly for assembly die casting wherein at least two preformed components are secured together in exact and predetermined relationship by die casting metal in a positionto engage and hold the parts as desired.
  • An important object of the invention consists in the provision of die mounting means of universal use, effective to meet various conditions imposed by the type of dies, their positional needs and the degree of angular movement desired to move them onto or oif the casting nozzle.
  • Another important object of the invention consists in providing means for accommodating and mounting dies required to pivot on a single axis as well as those with two-axis mounting requirements and which permits proper angular presentation of the die gate of either type to the casting nozzle.
  • Still another important object of the invention consists in the unique construction of the die mounting and operating means whereby the length of stroke imparted thereto for on and off nozzle positions may be readily adjusted to suit the peculiarities of the die construction.
  • a further important object of the invention consists in the pro-vision of position adjustment for the die moving means independent of stroke length adjustment whereby proper pressure is achieved between the casting nozzle and the die gate walls.
  • a still further important object of the invention consists in controlling the initiation of the casting operation on the termination of the on nozzle stroke by mechanism associated with the die stroke drive means in such manner that the initiation time is wholly independent of the stroke length and stop position adjustments.
  • Essential features of the invention involve: the provision for injection of the casting metal independently of the angular position of the die which permits die loading as dictated by the construction thereof and the parts to be assembled therein; use of simple removable pin or pins for mounting the dies; simple adjustment of crank pin position for stroke length control; same are of rotation for crank pin independent of die stroke length; and adaptability of the apparatus for full or semi-automatic operation.
  • Fig. 1 is a perspective view of a complete die casting machine incorporating the apparatus of the present invention
  • Fig. 2 is a vertical section through the basic casting components of such a die casting machine equipped with the improvements of the present invention
  • Figure 3 is a vertical section through the power mechanism and actuator for moving the casting die onto and off of the nozzle, the section being taken on the plane of broken line 3-3 of Fig. 4;
  • Fig. 4 is a transverse section taken on the plane of line 4-4 of Fig. 3 and illustrating more of the actuator mechanism including the adjustable eccentricity crank pin, the driver link, the adjustable mounting for the whole actuator assembly and other features;
  • Fig. 5 is a fragmentary transverse section on line 55 of Fig. 4;
  • Fig. 6 is an elevation of the upper portion of the actuator assembly viewed from the left of Fig. 4;
  • Fig. 7 is a central section through the actuator crank and adjustable crank pin
  • Fig. 8 is an end elevation thereof
  • Fig. 9 is a side elevation thereof
  • Fig. 10 is a side elevation of the complete actuator mechanism positioned on the die carrier H-bracket support and fulcra assembly;
  • Fig. 11 is an edge elevation thereof
  • Fig. 12 is a side elevation of the inclined H-bracket supporting the fulcra and crank means for actuating the die carrier, portions being shown in section to illustrate the construction;
  • Fig. 13 is a diagrammatic illustration of the two-axis mounting arrangement for a die the actuating and adjusting mechanism.
  • Fig. 14 is a view similar to Fig. 13 but showing the single axis mounting for the die carrier.
  • Assembly die casting involves the securing together of two or more previously manufactured non-die cast components into a rigid assembly by the use of small quantities of die cast metal forming the connections between the components. Such operations are particularly desirable in the mounting of small gears and pinions on spindles or shafts, the mounting of aluminum drag disks on the arma ture spindles of electric power meters and for an infinite variety of similar purposes.
  • the die In such assembly die casting the die must be separable into at least two parts and must provide facilities for mounting rigidly in their appropriate relationships the carrier, and illustrating sesame them rigidly in position while the die casting metal is injected into the spaces between and around them for providing the connection.
  • the requirements for the angular positioning of the die when open will vary in order that these parts will not fall out while the die sections are brought together.
  • the position of the gate through which the casting metal is injected and which must engage over the injection nozzle is to a large degree determined by the shapes of the components to be joined together and the required positioning of the die casting thereon.
  • Fig. I an automatic machine for performing assembly die castings and it comprises a base it, a standard 12 and an extension panel board 13.
  • the standard 12 houses hydraulic or pneumatic and electrical equipment necessary for the various operations but which form but little part of the present invention, and the panel board portion 13 mounts the necessary instruments, gauges, control valves, switches and the like for the setting, timing and manipulation of the various operations.
  • the melting pot housing 15 Near the upper front portion of the standard 12 is mounted the melting pot housing 15 and at 16 is shown the die carrier and die assembly positioned to cooperate with the injection nozzle, later to be described, extending from the melting pot.
  • the assembly for supporting and actuating the die carrier is indicated by the reference character 17 and together with the die and the melting pot will be seen in greater detail in the partial vertical section through some of these elements, as shown in Fig. 2.
  • the melting pot 19 is in the form of a crucible for holding the molten metal 20, shown therein. Heat may be provided to maintain liquidity by suitable electric heaters 21 and an insulating sleeve 22 surrounding the pot prevents excessive loss of heat as does the cover plate 18 from which it is suspended.
  • That portion of the cover plate which is rigid and permanent is securely attached to the standard of the machine and extends to support all of the parts illustrated in Fig. 2, and particularly the nozzle pump unit 23 shown beneath the cover plate and within the melting pot.
  • This part is generally conventional and need be described only briefly as including a cylindrical bore 24 having a passage 25 uncovered by the piston 26 when withdrawn to allow the lower portion of the bore to be filled.
  • the plunger When the plunger is depressed it shuts oif passage 25 and ejects the molten metal from the bore 24 through delivery duct 26 to nozzle 27 which cooperates with a gate 28 in the die for injecting the molten metal therein.
  • Operation of the plunger 26 is through a link and pivoted pump lever 28 provided for either manual operation, or automatic operation by means of a twoway pneumatic cylinder 30, the controls for which are contained in the standard of the machine as previously mentioned.
  • the pneumatic hoses illustrated connected to the cylinder 30 selectively receive air for injection and withdrawal of the plunger through a valve actuated by an electric initiating mechanism, the circuit of which is under the control of one of the parts which will be later described.
  • the injection nozzle 27 extends outwardly and upwardly to the left to be available to the gate in the die mounted in the die carrier 34
  • the injection nozzle is tapered to a narrow conical end and should be received in the conical gate 28 in the die itself so that the axes of the gate cone and the nozzle cone are substantially coincidental and with adequate pressure to prevent leakage where they mate.
  • Such contact between these parts is achieved by the mechanism generally designated 17 in Fig. l and including the die carrier 3% and positioning and moving means for the latter including supporting H-frame 32 rigidly carried from and supported by the main portion of the frame of the machine, which may extend from the cover 18 of the die pot.
  • Such a portion of the machine is seen at 33 and the H-frame 32 is appropriately secured thereto at the angle shown and from its lower end supports the carrier bracket 34 for the adjustable actuator housing 35.
  • the die carrier 3% comprises a frame the shape of which depends to a large extent on the type of dies which must be accommodated therein.
  • the lower, U-shaped portion has a large head 37 which accommodates stationary die portion 38, shown as of the type containing the injection gate 28 at an angle to the general axis of the die in order that it may introduce the die metal, shown at ltl, between the pro-formed disk 41 and its spindle 42.
  • This dish is illustrated as resting against a properly shaped surface on the stationary die part 38, but it is engaged about its edges and positioned by a circumferential flange on the movable die part 43, which itself is received within the circumferential flange of the stationary die part to insure adequate and accurate location.
  • tubular extension 45 of die part 43 are guiding and holding means for spindle 42, the lower end of which passes through disl; 4i and is held in a guide in the stationary die part.
  • the two parts of the die are brought into engagement as shown so that the disk and spindle are rigidly held in proper relationship to each other ready to receive the injected metal 40 which secures them together. They are then relatively rotated for approximately one-eighth turn to provide suitable locking, by mechanism not shown, and the reverse of this operation for unlocking serves to cut off the sprue' since the disk its now assembled parts is held for rotation with the movable die member and thus severs the sprue right at the tip of the gate.
  • the ejection pin 4-7 is actuated by handle 48 to separate the assembly from the now open movable portion of the die and it is removed by hand and new components inserted.
  • the nozzle enters at a substantial angle to the axes of the dies and the components are initially loaded in the movable die portion so that the carrier must tilt the die to a position where the axis thereof is reversely inclined from that shown in order that the parts will remain in position in the die when first dropped in and before the die parts are brought together.
  • the gate may be on the axis of the stationary die part and this part may receive the elements to be assembled rather than the movable die section which requires a different angular presentation of the assemblage to the nozzle and a dilferent position for loading. All of these and many others may be achieved by the unusual mounting facilities provided by the mechanism illustrated.
  • Figs. 2 and 14 Illustrated in Figs. 2 and 14 is a representative die and carrier adapted for single point mounting and arcuate movement in a path from on to off the nozzle.
  • the H-frame 32 carries the mechanism for supporting and moving the carrier, and this H-frame as shown foreshortened but in elevation in Fig. 12 comprises a pair of parallel, spaced, side arms t adapted to be suitably secured to the part 33 of the machine.
  • the cross bar 51 which provides adequate rigidity the arms 5d are somewhat thinner laterally and support between bushings therein a shaft 52 rotatable by means of a crank arm 53 keyed thereto.
  • the sleeve 54 having the spaced radial arms 55 fitting closely between the arms 50 and each fitted with a bored bushing 56. Through the bushings a pin 57 (Fig. is received and longitudinally positioned in any suitable manner.
  • the carrier for the die is in accordance with Figs. 2 and 14 fitted with either a pair of transversely spaced brackets 53 or a single wide one rigidly attached thereto in any desired manner and extending below the U-shaped portion of the carrier. Close to the carrier they are perforated to accommodate the pin 57 and provide the proper width to fit closely between the faces of the bushings as so that when pin 57 is pressed into position the carrier is secured to the arms 55.
  • the lower end of the bracket is forked, as seen at on in Fig. 2, and the furcations have straight parallel inner faces spaced apart exactly the same distance as the diameter of sleeve 54 which joins arms 55 to each other.
  • the carrier when the carrier is mounted so that the fork fits over the sleeve and the pin 57 passes through the bracket openings and through bushings 56 the carrier is rigidly secured and movable with the U-shaped element 55, 54, 55 so that upon movement of the crank arm 53 the die may travel in an arcuate path toward or from the injection nozzle.
  • Movement is imparted to the crank arm 53 by means of a link 62 fulcrumed to the outer end thereof. Regulation of the length of stroke imparted to the link 62 by mechanism which will be later described and an adjustment of the initial position of the link permits a determination of the length of the stroke of the die carrier and the regulation of the stopping of it in the on position with the gate properly pressed against the injection nozzle.
  • Dies requiring a path of movement more nearly approaching a straight line in order to accommodate certain positions of the gate are accommodated with mechanism similar to that just described plus several additional parts, as illustrated in Figs. ll and 13.
  • the die carrier 36 is fitted with two longitudinally spaced brackets 65 and 66.
  • the one nearer to the gate is, however, a simple bracket having a single hole therein to accommodate the pin 57. There is no forked extension.
  • the other bracket, near the rear end of the carrier, is similar inconstruction and is linked to the fixed cross pin 63 (seen in Fig. 12) at the lower portion of the H-frame 32.
  • a link unit 69 comprising a sleeve and a pair of spaced links 70, each provided with a bushed opening 71.
  • These links receive between them the bracket 66 and pin 72 passes through the hole in bracket 66 and holes 71 in links 70.
  • the links designated 70 are free moving but the attachment of the forward bracket to arms 55 fixed tothe sleeve 54 controls the driving of the carrier while the links merely help determine the path in which it moves.
  • the links '70 are merely thrown to one side out of the way, ready for use when the dual axis mounting is desired.
  • crank pin 75 which is adjustable in eccentricity in relation to crankshaft 76 which is mounted in the spaced double row ball bearings carried in casting '77 preferably formed integral with the sides, bottom, top and front walls of the open sided box designated 35 in many of the figures.
  • the open side of this box is closed by cover plate 78.
  • the bearings for the crankshaft '76 are spaced by a sleeve asshown, positioned in the casting by a pin secured as illustrated in Fig. 5. As seen in both Figs.
  • crankshaft to the left end of the hearing assembly, is fitted with an attached pinion 80 which meshes with a gear sector 81 mounted on shaft 82 pivoted between two sets of ball bearings mounted in the casting 77, as clearly seen at the lower part of Fig. 4.
  • the gear sector 81 is imparted a stroke in either direction of fixed length by means of rod 35 of a piston mounted in air cylinder 86 pivoted at $7 at its lower end to the bottom of housing 35. .
  • the upper end of the piston rod is pivoted to an ear on the sector gear at 38, and air hoses connected to the nipples 89 and 961 at opposite ends of the cylinder 86 permit the movement of the sector gear in either direction under the action of compressed air.
  • crankshaft 7.6 is seen to have an integral enlarged crank head 91 outside of housing 35 and provided with a transverse slot 92 of a Width to accommodate link 62 which fits over the crank pin.
  • Traveller 94 is adjustable longitudinally in channel 93 by means of screw 96 threaded therein and having the circumferential groove 97 in its head positioned by the arms of a fork extending from washer 98 which fits in a recess in head 91, as seen in Fig. 8, and holds the traveller therein. Adjustment of screw 96 by a screw driver in its kerf permits obtaining any degree of eccentricity within the range of the crank pin, and thus any desired length of stroke for the die carrier may be achieved.
  • the hand wheel 106 is suitably secured over washer 98 to the crank head and radially slotted to pass pin 99 extending from travel-ler 94 on the opposite side from crank pin '75.
  • This hand wheel may be used for manipulating the mechanism when making the initial adjustment to insure the proper contacting of the gate surfaces with those of the injecticn nozzle.
  • the slot in the hand wheel may be bushed, as shown, the edges of the bushing being graduated as seen in Fig. 11 to correspond with an index mark on a washer over pin 99 to indicate the degree of eccentricity.
  • the assemblage of actuator mechanism carried by housing 35 and which drives link 62. is not fixedly attached to the frame of the machine, but is adjustable from and toward the crank 53 in a direction substantially parallel to the plane of H bracket 32 and the mounting permitting this adjustment is best seen in Figs. 3, 4 and 10. It will be remembered that the lower end of the H- bracket has attached thereto a bracket 34 and the under surface of this is formed with a dovetail guideway 102, to
  • crankshaft 76 extends through cover plate 78 and is fittedsuccessively beyond pinion 80 with aspacer 115, the hub 116 ofa switch actuator, a washer 117 and a locking ring 118.
  • the hub 116 has cast integral therewith arms 1%, 121, and they as well as-the hub are divided by a radial slot 122 so that a screw, the head 123 of which appears in Fig. 6, may pass transversely across this slot withthe screw engaged in the part 121 to constrict the hub and clamp it in any angularly adjusted position on shaft to.
  • Switch 128 is in control of the electric circuit which initiates the air control for the injector pump actuator cylinder 30 previously referred to.
  • this switch can becaused to close exactly at the end of the stroke of the crankshaft which it will be remembered always moves through exactly the same arc, so that as soon as the gate is properly positioned over the 'injector'nozzle the pump is actuated and the molten metal injected into the die.
  • the various adjustments which can be achieved to position the switch actuator to close the switch exactly at the end of the stroke need be made but once, and thereafter the operation is wholly independent of the positioning of the actuator housing 35, or on the eccentricity of the crank pin. So long as the gate is adjusted to exactly fit over the injector nozzle the switch will start the actuation of the injector pump at the instant this is achieved no matter what the stroke-of the die carrier or the angleto which it is presented to the injector nozzle.
  • a fixed injectionnozzle having a pointed conical end, meansto force molten metal from a source through said nozzle
  • a casting die comprising at least two separable parts, one part having a gate for engagement over said nozzle end to receive metal therefrom, a die carrier adaptedto hold the die parts assembled, means to support said carrier for movement of the die from an or position to gate engagement on said nozzle, having a frame part fixed in relation to the nozzle, a driver arm fulcrumed to said frame part, means to pivotall'y connect said arm and said-carrier together, means articulating the fraine'and carrier and means to actuate said driver arm to move the die between the off and on positions 2.
  • the means to pivot the arm and carrier comprises a part on each having frame and carriercomprisesa fork on the'carrier adapted to closely and rotatably engage over means coaxial to the fulcrum for said driver arm.
  • the meansto pivot the arm and carrier comprises a part on each having a hole to receive a pin, a second part on said carrierhaving a hole with the axis parallel to that of the first hole, alink pivoted to said frame part remote from the axis of said arm and having a hole in its free end to receive a pin engaging in said last mentioned hole.
  • the means to actuate said driver arm comprising a crank having a crankpin, a link connecting said crankpin to said arm, means to adjust the eccentricity of'said crankpin and means to rotate said crank through a fixed are to provide each on or off carrier movement.
  • crank is adjustable in position in relation to said driver arm to determine the final position of the gate in respect to the nozzle.
  • the apparatus as defined in claim 5 including elec tric means to initiate the means to force molten metal through the nozzle, a-shaft mounting said crank, an electric switch-adjacent said shaft and connected to control said electric means, operating means ousaid shaft for said switch and means to adjust said last mentioned means in respectto said shaft to actuate the switch substantially at the end of each on movement of the die, whereby the latter adjustment can remain fixed in spite of changes in the length and orbit of the movement.
  • die carrier adapted to hold the die parts; means to support said carrier for movement to engagethe gate over the nozzle or Withdraw the carrier to an unloading position for the dies-comprising a frame member fixed in relation to said nozzle, a pair of spaced, parallel-axes, fulcra on said member, a driver arm and a link pivoted respectively on said fulcra and each having a circular hole at its remote end with the hole axis parallel to those of the fulcra, pins extending through said holes and engaged in said carrier at spaced positions thereon, and means to move said driver arm about its fulcrum to advance the die to on nozzle or retract it to unloading position.
  • crankpin adjustable in eccentricity on said crank, said link connecting said crankpin to said driver arm.
  • an injection nozzle means to deliver molten metal through said nozzle, casting die having separable parts one of 'Which has a gate for engagement over'said nozzle to receive metal therefrom, a die carrier adapted to hold the die parts; means to support engage thevgate to an unloading member fixed in relation to said nozzle, a shaft pivoted for rotation in said frame and having a pair of spaced driver arms extending therefrom, each having a hole in the free end thereof, an extension on said carrier hav ing a lug thereon adapted to fit between said arms and having a hole in alignment with those in the arms, a pin. in said aligned holes, and an extension of said lug having a forked end closely engaging over said shaft to hold the carrier rigid with said arms for movement therewith, and means to move said shaft to engage the gate with said nozzle or Withdraw the die therefrom.
  • the actuator includes a crank, means to move said crank always through a fixed are, a crank pin, means to manually adjust the eccentricity of said crankpin, said link connecting said crankpin to actuate said shaft.

Description

M y mm W. F. FISHER zmmm ASSEMBLY DIE CASTING APPARATUS Filed Sept. 7, 1.956 6 Sheets-Sheet 1 us A E 33 l/IO /7 g a Q 54 Q T 1* f FIG.
. INVENTOR WILL/AM F FISHER ATTORNEYS W W W. F. FISHER ,32,W
ASSEMBLY DIE CASTING APPARATUS mm 58p? 7, 1956 6 Sheets-Sheet 2 Q "3 W v ia Im II! I WILL/AM F FISHER :2
ATTORNEYS April 29, 1958 w. F. FISHER .ASSEMBLY DIE CASTING APPARATUS 6 Sheets-Sheet 3 Filed Sept. 7, 1956 Q2 mm mm, A m .w k
k\\\\\\\\\ IIIIIIIIIIII'III INVENTOR WILLIAM F. FISHER ATTORNEYS April 29, 1958 w. F, FISHER 2,832,109
ASSEMBLY DIE CASTING APPARATUS Filed Sept. 7. 1956 6 Sheets-Sheet 4 INVENTOR WILLIAM E FISHER ATTORNEYS April 1953 w. F. FISHER 2,832,109
ASSEMBLY DIE CASTING APPARATUS 6 Sheets-Sheet 5 Filed Sept. 7, 1956 INVENTOR W/LMM F. FISHER ATTORNEYS April 1958 w. F. FISHER ASSEMBLY DIE CASTING APPARATUS 6 Sheets-Sheet 6 Filed Sept. 7, 1956 ATTORNEYS United? States if) ASSEMBLY DIE CASTING APPARATUS William F. Fisher, Peterborough, Ontario, Canada, as-
signor to Fisher Gauge Works Limited, Peterborough, Qntario, Canada, a corporation of Canada Application September 7, 1956, Serial No. 608,607
15 Claims. (Cl. 22-68) This invention relates to die casting apparatus and more particularly to such apparatus of fully or semi-automatic character, intended primarily but not wholly for assembly die casting wherein at least two preformed components are secured together in exact and predetermined relationship by die casting metal in a positionto engage and hold the parts as desired.
It is a general object of the present invention to provide novel and improved apparatus for assembly die casting.
More specifically it is an object of the present invention to provide apparatus to facilitate die casting or assembly die casting by improved mounting means for the die whereby its movement onto and oif the casting nozzle is more effectively controllable.
An important object of the invention consists in the provision of die mounting means of universal use, effective to meet various conditions imposed by the type of dies, their positional needs and the degree of angular movement desired to move them onto or oif the casting nozzle.
Another important object of the invention consists in providing means for accommodating and mounting dies required to pivot on a single axis as well as those with two-axis mounting requirements and which permits proper angular presentation of the die gate of either type to the casting nozzle.
Still another important object of the invention consists in the unique construction of the die mounting and operating means whereby the length of stroke imparted thereto for on and off nozzle positions may be readily adjusted to suit the peculiarities of the die construction.
A further important object of the invention consists in the pro-vision of position adjustment for the die moving means independent of stroke length adjustment whereby proper pressure is achieved between the casting nozzle and the die gate walls.
A still further important object of the invention consists in controlling the initiation of the casting operation on the termination of the on nozzle stroke by mechanism associated with the die stroke drive means in such manner that the initiation time is wholly independent of the stroke length and stop position adjustments.
Essential features of the invention involve: the provision for injection of the casting metal independently of the angular position of the die which permits die loading as dictated by the construction thereof and the parts to be assembled therein; use of simple removable pin or pins for mounting the dies; simple adjustment of crank pin position for stroke length control; same are of rotation for crank pin independent of die stroke length; and adaptability of the apparatus for full or semi-automatic operation.
Other and further objects and features of the invention will be more apparent to those skilled in the art upon a consideration of the following specification and accompanying drawings wherein is disclosed a single exemplary embodiment of the invention, with the understanding that such changes and modifications may be made therein as 1 several preliminarily formed components and must hold M fall within the scope of the appended claims, without departing from the spirit of the invention.
In said drawings;
Fig. 1 is a perspective view of a complete die casting machine incorporating the apparatus of the present invention;
Fig. 2 is a vertical section through the basic casting components of such a die casting machine equipped with the improvements of the present invention;
Figure 3 is a vertical section through the power mechanism and actuator for moving the casting die onto and off of the nozzle, the section being taken on the plane of broken line 3-3 of Fig. 4;
Fig. 4 is a transverse section taken on the plane of line 4-4 of Fig. 3 and illustrating more of the actuator mechanism including the adjustable eccentricity crank pin, the driver link, the adjustable mounting for the whole actuator assembly and other features;
Fig. 5 is a fragmentary transverse section on line 55 of Fig. 4;
Fig. 6 is an elevation of the upper portion of the actuator assembly viewed from the left of Fig. 4;
Fig. 7 is a central section through the actuator crank and adjustable crank pin;
Fig. 8 is an end elevation thereof;
Fig. 9 is a side elevation thereof;
Fig. 10 is a side elevation of the complete actuator mechanism positioned on the die carrier H-bracket support and fulcra assembly;
Fig. 11 is an edge elevation thereof;
Fig. 12 is a side elevation of the inclined H-bracket supporting the fulcra and crank means for actuating the die carrier, portions being shown in section to illustrate the construction;
Fig. 13 is a diagrammatic illustration of the two-axis mounting arrangement for a die the actuating and adjusting mechanism; and
Fig. 14 is a view similar to Fig. 13 but showing the single axis mounting for the die carrier.
In the manufacture of die castings it is highly desirable to provide apparatus capable of automatic or semi-automatic operation for considerable time and elfort on the part of the operator is thereby saved and the percentage of perfect castings is materially increased. Automatic timing of certain of the operations, particularly the length of the cooling phase, is essential to insure against opening the dies while portions of the cast are still molten.
When die casting is used as an automatic assembly operation, the requirements becomes even more severe, for it is highly desirable that the die become an entirely separate unit with means provided for bringing it into contact with the casting nozzle on each casting cycle. The requirements for rapid interchangeability of dies necessitate a mounting mechanism which is extremely versatile and capable of accommodating a variety of dies. It should be adjustable for scope, position and path of operation, with change-over time as short as possible and the operation required to make the change simple and with few parts.
Assembly die casting involves the securing together of two or more previously manufactured non-die cast components into a rigid assembly by the use of small quantities of die cast metal forming the connections between the components. Such operations are particularly desirable in the mounting of small gears and pinions on spindles or shafts, the mounting of aluminum drag disks on the arma ture spindles of electric power meters and for an infinite variety of similar purposes.
In such assembly die casting the die must be separable into at least two parts and must provide facilities for mounting rigidly in their appropriate relationships the carrier, and illustrating sesame them rigidly in position while the die casting metal is injected into the spaces between and around them for providing the connection. Depending upon which portion of the separable die the preformed components are mounted in, the requirements for the angular positioning of the die when open will vary in order that these parts will not fall out while the die sections are brought together. Moreover, the position of the gate through which the casting metal is injected and which must engage over the injection nozzle is to a large degree determined by the shapes of the components to be joined together and the required positioning of the die casting thereon. These two different requirements therefore necessitate some means for carrying the dies for movement of the gate onto and off of the injection nozzle, whereby the die may be stopped properly in the on position and at the proper angular relationship in the off position. This requires a versatility in stroke length, angularity of position both in the on and off stations, and a requirement of path of movement between the two stations capable of properly bringing the gate and die together. Most of these requirements are not essential for conventional die casting.
For a better understanding of the invention reference should be had first to Figs. 1 and 2 of the drawings. In Fig. I is shown an automatic machine for performing assembly die castings and it comprises a base it, a standard 12 and an extension panel board 13. The standard 12 houses hydraulic or pneumatic and electrical equipment necessary for the various operations but which form but little part of the present invention, and the panel board portion 13 mounts the necessary instruments, gauges, control valves, switches and the like for the setting, timing and manipulation of the various operations.
Near the upper front portion of the standard 12 is mounted the melting pot housing 15 and at 16 is shown the die carrier and die assembly positioned to cooperate with the injection nozzle, later to be described, extending from the melting pot. The assembly for supporting and actuating the die carrier is indicated by the reference character 17 and together with the die and the melting pot will be seen in greater detail in the partial vertical section through some of these elements, as shown in Fig. 2. Here the housing 15 for the melting pot and its supporting plate and frame part 18 are clearly seen, both being broken away for better view of the interior. The melting pot 19 is in the form of a crucible for holding the molten metal 20, shown therein. Heat may be provided to maintain liquidity by suitable electric heaters 21 and an insulating sleeve 22 surrounding the pot prevents excessive loss of heat as does the cover plate 18 from which it is suspended.
That portion of the cover plate which is rigid and permanent is securely attached to the standard of the machine and extends to support all of the parts illustrated in Fig. 2, and particularly the nozzle pump unit 23 shown beneath the cover plate and within the melting pot. This part is generally conventional and need be described only briefly as including a cylindrical bore 24 having a passage 25 uncovered by the piston 26 when withdrawn to allow the lower portion of the bore to be filled. When the plunger is depressed it shuts oif passage 25 and ejects the molten metal from the bore 24 through delivery duct 26 to nozzle 27 which cooperates with a gate 28 in the die for injecting the molten metal therein. Operation of the plunger 26 is through a link and pivoted pump lever 28 provided for either manual operation, or automatic operation by means of a twoway pneumatic cylinder 30, the controls for which are contained in the standard of the machine as previously mentioned. The pneumatic hoses illustrated connected to the cylinder 30 selectively receive air for injection and withdrawal of the plunger through a valve actuated by an electric initiating mechanism, the circuit of which is under the control of one of the parts which will be later described.
The injection nozzle 27 extends outwardly and upwardly to the left to be available to the gate in the die mounted in the die carrier 34 The injection nozzle is tapered to a narrow conical end and should be received in the conical gate 28 in the die itself so that the axes of the gate cone and the nozzle cone are substantially coincidental and with adequate pressure to prevent leakage where they mate. Such contact between these parts is achieved by the mechanism generally designated 17 in Fig. l and including the die carrier 3% and positioning and moving means for the latter including supporting H-frame 32 rigidly carried from and supported by the main portion of the frame of the machine, which may extend from the cover 18 of the die pot. Such a portion of the machine is seen at 33 and the H-frame 32 is appropriately secured thereto at the angle shown and from its lower end supports the carrier bracket 34 for the adjustable actuator housing 35.
As further seen in Fig. 2, the die carrier 3% comprises a frame the shape of which depends to a large extent on the type of dies which must be accommodated therein. As shown here the lower, U-shaped portion has a large head 37 which accommodates stationary die portion 38, shown as of the type containing the injection gate 28 at an angle to the general axis of the die in order that it may introduce the die metal, shown at ltl, between the pro-formed disk 41 and its spindle 42. This dish is illustrated as resting against a properly shaped surface on the stationary die part 38, but it is engaged about its edges and positioned by a circumferential flange on the movable die part 43, which itself is received within the circumferential flange of the stationary die part to insure adequate and accurate location. In tubular extension 45 of die part 43 are guiding and holding means for spindle 42, the lower end of which passes through disl; 4i and is held in a guide in the stationary die part.
The two parts of the die are brought into engagement as shown so that the disk and spindle are rigidly held in proper relationship to each other ready to receive the injected metal 40 which secures them together. They are then relatively rotated for approximately one-eighth turn to provide suitable locking, by mechanism not shown, and the reverse of this operation for unlocking serves to cut off the sprue' since the disk its now assembled parts is held for rotation with the movable die member and thus severs the sprue right at the tip of the gate. After the dies are opened by hand or by mechanism which may be provided but which is not illustrated except by the hoses St in Fig. 1 leading up to the actuating mechanism therefor, the ejection pin 4-7 is actuated by handle 48 to separate the assembly from the now open movable portion of the die and it is removed by hand and new components inserted.
In the construction illustrated, the nozzle enters at a substantial angle to the axes of the dies and the components are initially loaded in the movable die portion so that the carrier must tilt the die to a position where the axis thereof is reversely inclined from that shown in order that the parts will remain in position in the die when first dropped in and before the die parts are brought together. In other constructions the gate may be on the axis of the stationary die part and this part may receive the elements to be assembled rather than the movable die section which requires a different angular presentation of the assemblage to the nozzle and a dilferent position for loading. All of these and many others may be achieved by the unusual mounting facilities provided by the mechanism illustrated.
The position of the injection nozzle being fixed in respect to the frame of the die casting machine and its angle more or less dictated by structural features, it will be clear that for its axis to coincide with that of the gate in the die, which for reasons of shape, location of the injected insert, type of loading position necessary, and other factors, may not be positioned at the same angle to the axis of the die as illustrated in Fig. 2, certain adjustments must be provided. in order that the gate slide properly over the injection nozzle its course during movement from die open position to on position must be subject to some control. Certain dies will require nearly a straight line movement for proper accommodation of nozzle and gate, and for this purpose a dual axis support of the die carrier is provided for by features of the invention. Other and simpler die constructions are adaptable to an arcuate movement of the die carrier and for this purpose the construction provides for mounting of the die on the actuating mechanism by means of a single pin which holds it rigidly in respect to an arm which moves it in an are about a fixed center to advance toward the injection nozzle.
Illustrated in Figs. 2 and 14 is a representative die and carrier adapted for single point mounting and arcuate movement in a path from on to off the nozzle. As before mentioned the H-frame 32 carries the mechanism for supporting and moving the carrier, and this H-frame as shown foreshortened but in elevation in Fig. 12 comprises a pair of parallel, spaced, side arms t adapted to be suitably secured to the part 33 of the machine. Above the cross bar 51 which provides adequate rigidity the arms 5d are somewhat thinner laterally and support between bushings therein a shaft 52 rotatable by means of a crank arm 53 keyed thereto. Between the arms 50 and secured to rotate with the shaft 52 is the sleeve 54 having the spaced radial arms 55 fitting closely between the arms 50 and each fitted with a bored bushing 56. Through the bushings a pin 57 (Fig. is received and longitudinally positioned in any suitable manner.
The carrier for the die, numbered 30 in the various figures, is in accordance with Figs. 2 and 14 fitted with either a pair of transversely spaced brackets 53 or a single wide one rigidly attached thereto in any desired manner and extending below the U-shaped portion of the carrier. Close to the carrier they are perforated to accommodate the pin 57 and provide the proper width to fit closely between the faces of the bushings as so that when pin 57 is pressed into position the carrier is secured to the arms 55. The lower end of the bracket is forked, as seen at on in Fig. 2, and the furcations have straight parallel inner faces spaced apart exactly the same distance as the diameter of sleeve 54 which joins arms 55 to each other. Thus when the carrier is mounted so that the fork fits over the sleeve and the pin 57 passes through the bracket openings and through bushings 56 the carrier is rigidly secured and movable with the U-shaped element 55, 54, 55 so that upon movement of the crank arm 53 the die may travel in an arcuate path toward or from the injection nozzle.
Movement is imparted to the crank arm 53 by means of a link 62 fulcrumed to the outer end thereof. Regulation of the length of stroke imparted to the link 62 by mechanism which will be later described and an adjustment of the initial position of the link permits a determination of the length of the stroke of the die carrier and the regulation of the stopping of it in the on position with the gate properly pressed against the injection nozzle.
Dies requiring a path of movement more nearly approaching a straight line in order to accommodate certain positions of the gate are accommodated with mechanism similar to that just described plus several additional parts, as illustrated in Figs. ll and 13. Here the die carrier 36 is fitted with two longitudinally spaced brackets 65 and 66. The one nearer to the gate is, however, a simple bracket having a single hole therein to accommodate the pin 57. There is no forked extension. The other bracket, near the rear end of the carrier, is similar inconstruction and is linked to the fixed cross pin 63 (seen in Fig. 12) at the lower portion of the H-frame 32. On this is mounted a link unit 69, comprising a sleeve and a pair of spaced links 70, each provided with a bushed opening 71. These links receive between them the bracket 66 and pin 72 passes through the hole in bracket 66 and holes 71 in links 70. The links designated 70 are free moving but the attachment of the forward bracket to arms 55 fixed tothe sleeve 54 controls the driving of the carrier while the links merely help determine the path in which it moves. Obviously when using the single pin mounting of Fig. 14 the links '70 are merely thrown to one side out of the way, ready for use when the dual axis mounting is desired.
Link 62 which rotates the crank arm 53 is shown in Fig. 4 mounted on a crank pin 75 which is adjustable in eccentricity in relation to crankshaft 76 which is mounted in the spaced double row ball bearings carried in casting '77 preferably formed integral with the sides, bottom, top and front walls of the open sided box designated 35 in many of the figures. The open side of this box is closed by cover plate 78. The bearings for the crankshaft '76 are spaced by a sleeve asshown, positioned in the casting by a pin secured as illustrated in Fig. 5. As seen in both Figs. 3 and 4, the crankshaft, to the left end of the hearing assembly, is fitted with an attached pinion 80 which meshes with a gear sector 81 mounted on shaft 82 pivoted between two sets of ball bearings mounted in the casting 77, as clearly seen at the lower part of Fig. 4. The gear sector 81 is imparted a stroke in either direction of fixed length by means of rod 35 of a piston mounted in air cylinder 86 pivoted at $7 at its lower end to the bottom of housing 35. .The upper end of the piston rod is pivoted to an ear on the sector gear at 38, and air hoses connected to the nipples 89 and 961 at opposite ends of the cylinder 86 permit the movement of the sector gear in either direction under the action of compressed air.
Although the stroke of the sector gear is always exactly the same, as limited by the piston stopping against the cylinder heads, and is preferably such as to give exactly of rotation to pinion 80 and crankshaft 76, nevertheless the stroke of the link, and hence of crank 53 and the die carrier, is adjustable by changing the eccentricity of crank pin 75, and the means for doing this is illustrated in Figs. 7, 8 and 9, where crankshaft 7.6 is seen to have an integral enlarged crank head 91 outside of housing 35 and provided with a transverse slot 92 of a Width to accommodate link 62 which fits over the crank pin. The remaining end portion of the head is narrowly channeled radially at 93 in which is slidable the traveller 94 having integral therewith andlaterally at one end thereof crank pin 75 extending into slot 92. Traveller 94 is adjustable longitudinally in channel 93 by means of screw 96 threaded therein and having the circumferential groove 97 in its head positioned by the arms of a fork extending from washer 98 which fits in a recess in head 91, as seen in Fig. 8, and holds the traveller therein. Adjustment of screw 96 by a screw driver in its kerf permits obtaining any degree of eccentricity within the range of the crank pin, and thus any desired length of stroke for the die carrier may be achieved. The hand wheel 106 is suitably secured over washer 98 to the crank head and radially slotted to pass pin 99 extending from travel-ler 94 on the opposite side from crank pin '75. This hand wheel may be used for manipulating the mechanism when making the initial adjustment to insure the proper contacting of the gate surfaces with those of the injecticn nozzle. The slot in the hand wheel may be bushed, as shown, the edges of the bushing being graduated as seen in Fig. 11 to correspond with an index mark on a washer over pin 99 to indicate the degree of eccentricity.
The assemblage of actuator mechanism carried by housing 35 and which drives link 62. is not fixedly attached to the frame of the machine, but is adjustable from and toward the crank 53 in a direction substantially parallel to the plane of H bracket 32 and the mounting permitting this adjustment is best seen in Figs. 3, 4 and 10. It will be remembered that the lower end of the H- bracket has attached thereto a bracket 34 and the under surface of this is formed with a dovetail guideway 102, to
assaieo:
;; bereceived in-a complementarily shaped channel inthe inclined corner face 103 of housing 35. These-two parts are-arranged to have a close slidingfit and longitudinal adjustment is effected by a large thumb nut 105 threaded onto stud 166 permanently fixed to housing 35 and parallel to the direct-ion of sliding. A circumferential channel it)? in the hub of the nut receives fork 108 of hook 199 secured to bracket 34, Thus as the nut is screwed on or off the stud the whole actuator assembly is slid toward or away from the crank to which the link is pivoted. This permits, after stroke length adjustment, movement of the die carrier to achieve the proper contact pressure of the walls-of the gate therein with thewalls'of the injector nozzle, and this adjustment has no effect or relationship to the length of stroke imparted to the die carrier.
A's seen in Fig. 4 the adjustment just described can be locked to hold the parts more securely together by meansof studs llti passing through elongated slots 111 in bracket 34 and threadedly engaged in the part 163.
A consideration of Figs. 4, 6 and 10 shows that crankshaft 76 extends through cover plate 78 and is fittedsuccessively beyond pinion 80 with aspacer 115, the hub 116 ofa switch actuator, a washer 117 and a locking ring 118. The hub 116 has cast integral therewith arms 1%, 121, and they as well as-the hub are divided by a radial slot 122 so that a screw, the head 123 of which appears in Fig. 6, may pass transversely across this slot withthe screw engaged in the part 121 to constrict the hub and clamp it in any angularly adjusted position on shaft to. Transversely through the longer arm 121i extends the threaded portion 124- of a screw having a large knurled head 1.2.5. The threaded portion 124 extends beyond radial face 126 of arm 121 to engage actuator 127 of a quick acting, short stroke electric snap switch 128 of the type commonly referred to as microswitch which is mounted on conduit head 129 for electric conductors.
Switch 128 is in control of the electric circuit which initiates the air control for the injector pump actuator cylinder 30 previously referred to. By adjustment of the collar 116 about the crankshaft 76 and adjustment of screw 124 which can then be locked in position by additional screw 130 this switch can becaused to close exactly at the end of the stroke of the crankshaft which it will be remembered always moves through exactly the same arc, so that as soon as the gate is properly positioned over the 'injector'nozzle the pump is actuated and the molten metal injected into the die. The various adjustments which can be achieved to position the switch actuator to close the switch exactly at the end of the stroke need be made but once, and thereafter the operation is wholly independent of the positioning of the actuator housing 35, or on the eccentricity of the crank pin. So long as the gate is adjusted to exactly fit over the injector nozzle the switch will start the actuation of the injector pump at the instant this is achieved no matter what the stroke-of the die carrier or the angleto which it is presented to the injector nozzle.
Iclaim:
1. In die casting apparatus, in combination, a fixed injectionnozzle having a pointed conical end, meansto force molten metal from a source through said nozzle, a casting die comprising at least two separable parts, one part having a gate for engagement over said nozzle end to receive metal therefrom, a die carrier adaptedto hold the die parts assembled, means to support said carrier for movement of the die from an or position to gate engagement on said nozzle, having a frame part fixed in relation to the nozzle, a driver arm fulcrumed to said frame part, means to pivotall'y connect said arm and said-carrier together, means articulating the fraine'and carrier and means to actuate said driver arm to move the die between the off and on positions 2.- The apparatus of claim 1 in which the means to pivot the arm and carrier comprises a part on each having frame and carriercomprisesa fork on the'carrier adapted to closely and rotatably engage over means coaxial to the fulcrum for said driver arm.
3. The apparatus of claim 1 in which the meansto pivot the arm and carrier comprises a part on each having a hole to receive a pin, a second part on said carrierhaving a hole with the axis parallel to that of the first hole, alink pivoted to said frame part remote from the axis of said arm and having a hole in its free end to receive a pin engaging in said last mentioned hole.
The apparatus as defined in claim 1 in whichthe means to actuate said driver armcomprising a crank having a crankpin, a link connecting said crankpin to said arm, means to adjust the eccentricity of'said crankpin and means to rotate said crank through a fixed are to provide each on or off carrier movement.
5. The apparatus as defined in claim 4 in which-said" crank is adjustable in position in relation to said driver arm to determine the final position of the gate in respect to the nozzle.
6. The apparatus as defined in claim 5 including elec tric means to initiate the means to force molten metal through the nozzle, a-shaft mounting said crank, an electric switch-adjacent said shaft and connected to control said electric means, operating means ousaid shaft for said switch and means to adjust said last mentioned means in respectto said shaft to actuate the switch substantially at the end of each on movement of the die, whereby the latter adjustment can remain fixed in spite of changes in the length and orbit of the movement.
7. The apparatus as defined in claim 5 including an electric control for said means to force molten'metal through said nozzle, 2. switch for said control and means responsive to the angular position of said crank for actuating said switch whereby it closes the switch at the end' of each on movement of the die'irrespective of the stroke or orbit of said movement.
8. In die casting apparatus in combination,- a fixed injection nozzle, means to deliver molten metal through said nozzle, a casting die having separable parts one of which has a gate for engagement over said nozzle to re-' ceive metal therefrom, a. die carrier adapted to hold the die parts; means to support said carrier for movement to engagethe gate over the nozzle or Withdraw the carrier to an unloading position for the dies-comprising a frame member fixed in relation to said nozzle, a pair of spaced, parallel-axes, fulcra on said member, a driver arm and a link pivoted respectively on said fulcra and each having a circular hole at its remote end with the hole axis parallel to those of the fulcra, pins extending through said holes and engaged in said carrier at spaced positions thereon, and means to move said driver arm about its fulcrum to advance the die to on nozzle or retract it to unloading position.
9. The apparatus of claim 8 in which a power actuator is carried by said frame member, link means connecting said. actuator and driver arm for moving the latter and means to adjust the position of the actuator on said frame member to regulate the die and gate engagement during the on position.
it). The apparatus of claim 9 in which the actuator includes a crank, means to movesaid crank through a.
fixed arc, and a crankpin adjustable in eccentricity on said crank, said link connecting said crankpin to said driver arm.
ll. in die casting apparatus incombination, an injection nozzle, means to deliver molten metal through said nozzle, casting die having separable parts one of 'Which has a gate for engagement over'said nozzle to receive metal therefrom, a die carrier adapted to hold the die parts; means to support engage thevgate to an unloading member fixed in relation to said nozzle, a shaft pivoted for rotation in said frame and having a pair of spaced driver arms extending therefrom, each having a hole in the free end thereof, an extension on said carrier hav ing a lug thereon adapted to fit between said arms and having a hole in alignment with those in the arms, a pin. in said aligned holes, and an extension of said lug having a forked end closely engaging over said shaft to hold the carrier rigid with said arms for movement therewith, and means to move said shaft to engage the gate with said nozzle or Withdraw the die therefrom.
12. The apparatus of claim 11 in which a power actuator is carried by said frame member, link means connecting said actuator and said shaft for imparting partial rotation thereto, and means to adjust the position of the actuator on said frame generally toward or from said shaft to regulate the die and gate engagement pressure.
13. The apparatus of claim 12 in which the actuator includes a crank, means to move said crank always through a fixed are, a crank pin, means to manually adjust the eccentricity of said crankpin, said link connecting said crankpin to actuate said shaft.
References Cited in the file of this patent UNKTED STATES PATENTS 937,477 Shonberg Oct. 19, 1909 1,013,665 Leddell Jan. 2, 1912 1,279,249 Eungay Sept. 17, 1918 1,476,765 Murray et al Dec. 11, 1923 1,618,223 Pierce Feb. 22, 1927 1,994,824 Kux Mar. 19, 1935 2,131,955 Johns-on Oct. 4, 1938 2,519,739 Eutner Aug. 22, 1950 2,775,009 Meldrum et a1. Dec. 25, 1956
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3151367A (en) * 1961-10-09 1964-10-06 Fmc Corp Feeding mechanism for die casting machine

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US937477A (en) * 1908-11-14 1909-10-19 Isaac Shoenberg Casting apparatus.
US1013665A (en) * 1909-05-06 1912-01-02 Henry F Merriam Die-casting apparatus.
US1279249A (en) * 1915-10-05 1918-09-17 Acme Die Casting Corp Casting apparatus.
US1476765A (en) * 1921-06-01 1923-12-11 Thomas E Murray Die-casting machine
US1618223A (en) * 1920-07-26 1927-02-22 Ernest P Pierce Die-casting machine
US1994824A (en) * 1933-08-10 1935-03-19 Albert S Kux Die casting machine
US2131955A (en) * 1935-11-21 1938-10-04 Imp Die Casting Company Die casting machine
US2519739A (en) * 1946-09-04 1950-08-22 Hydropress Inc Die-casting machine
US2775009A (en) * 1953-05-26 1956-12-25 Monotype Corp Ltd Pump mechanism for type casting machines

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US937477A (en) * 1908-11-14 1909-10-19 Isaac Shoenberg Casting apparatus.
US1013665A (en) * 1909-05-06 1912-01-02 Henry F Merriam Die-casting apparatus.
US1279249A (en) * 1915-10-05 1918-09-17 Acme Die Casting Corp Casting apparatus.
US1618223A (en) * 1920-07-26 1927-02-22 Ernest P Pierce Die-casting machine
US1476765A (en) * 1921-06-01 1923-12-11 Thomas E Murray Die-casting machine
US1994824A (en) * 1933-08-10 1935-03-19 Albert S Kux Die casting machine
US2131955A (en) * 1935-11-21 1938-10-04 Imp Die Casting Company Die casting machine
US2519739A (en) * 1946-09-04 1950-08-22 Hydropress Inc Die-casting machine
US2775009A (en) * 1953-05-26 1956-12-25 Monotype Corp Ltd Pump mechanism for type casting machines

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3151367A (en) * 1961-10-09 1964-10-06 Fmc Corp Feeding mechanism for die casting machine

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