US3749151A

US3749151A - Vibratory shakeout apparatus

Info

Publication number: US3749151A
Application number: US00247612A
Authority: US
Inventors: M George; N Kitchin; W Rose; D Varano; G Bronson
Original assignee: General Motors Corp
Current assignee: Motors Liquidation Co
Priority date: 1972-04-26
Filing date: 1972-04-26
Publication date: 1973-07-31
Anticipated expiration: 1990-07-31

Abstract

A vibratory shakeout apparatus including a pair of suspended, parallelly spaced, horizontally disposed vibrating rails mounted at the end of a continuously traveling conveyor carrying a row of contiguous, flaskless sand molds containing cast articles therein is disclosed. The vibrating rails pierce each of the molds and engage the casting therein as the molds are moved into the apparatus and advance the oriented castings to an end position on the rails, separating the sand therefrom, where the castings are removed from the apparatus by a programmed mechanical handling device.

Description

United States Patent [1 1 George et al.

[ VIBRATORY SHAKEOUT APPARATUS [75] Inventors: Michael D. George, Dayton;

Dominick J. Varano; George K. Bronson, both of Defiance, all of Ohio; Nelson L. Kitchin, Warren; William W. Rose, Jr., Ferndale, both of Mich.

[73] Assignee: General Motors Corporation,

' Detroit, Mich.

[22] Filed: Apr. 26, 1972 [21] App]. No.: 247,612

[52] U.S. Cl. 164/322, 164/187 [51] Int. Cl B22d 29/00 [58] Field 01 Search 164/187, 131, 260,

[56] References Cited UNITED STATES PATENTS 3,627,020 12/1971 Taccone 164/404 11 3,749,151 [451 July 31,1973

Primary Examiner-Gerald M. Forlenza Assistant m ri=J- O al! Attorney-Sidney Carter and Peter P. Kozak [57] ABSTRACT A vibratory shakeout apparatus including a pair of suspended, parallelly spaced, horizontally disposed vibrating rails mounted at the end of a continuously traveling conveyor carrying a row of contiguous, flaskless sand molds containing cast articles therein is disclosed. The vibrating rails pierce each of the molds and engage the casting therein as the molds are moved into the apparatus and advance the oriented castings to an end position on the rails, separating the sand therefrom, where the castings are removed from the apparatus by a programmed mechanical handling device.

7 Claims, 4 Drawing Figures Patented Jul 31, 1973 3,749,151

2 Sheets-Sheet l Patented July 31, 1973 3,749,151

2 Sheets-Sheet 2 VIBRATORY SI-IAKEOUT APPARATUS This invention relates to vibratory shakeout apparatus and, more particularly, to apparatus for use in combination with a continuously traveling row of contiguous, flaskless sand molds wherein the castings are removed from the molds, the sand separated therefrom, and the castings conveyed to an end position of the apparatus in an oriented position for removal therefrom.

In an effort to achieve increased automation of foundry casting processes, modern foundries are using automatic molding machines which produce a rectilinear row of flaskless sand molds. The use of such automatic apparatus permits the production of virtually finfree castings of high dimensional accuracy in a continuous, automatic mold forming and casting operation.

It has been conventional practice to remove cast articles from sand molds by moving the molds from the pouring and cooling line onto a horizontally disposed vibrating grate which breaks up the molds and vibrates the sand free from the castings with the sand falling through the openings in the grate to a collection bin below. In addition to the inherent objections of such systems, e.g., excessive noise and dust production, such shakeout apparatus are unsuitable for use with an automated mold forming and casting process. That is, these systems often result in random breaking of the casting or of its gating system. In an automated operation, it is desirable that the gating system remain intact for positioning of the casting in an automatic shearing apparatus. Furthermore, since highly dimensionally accurate castings are produced in anautomated operation, to preserve casting quality it is desirable that the castings not contact the shakeout apparatus. Still further, prior art systems moved the castings to the end of the shakeout bed in a completely random and disoriented manner. In an automated casting process, it is necessary that the castings be removed from the molds and conveyed through the shakeout system in an oriented fashion for further processing.

Accordingly, it is the principal object of this invention to provide an improved, automatic shakeout apparatus for use in combination with an automatic mold forming and casting line which sequentially removes the castings from the molds, separates the sand therefrom, and advances the castings to the end of the apparatus for removal from the casting line.

It is another object of our invention to provide automatic shakeout apparatus wherein the castings are removed from the molds and advanced in an oriented position to a position at the end of the apparatus for removal by an automatic mechanical handling device without the usable cast portion of the cast article contacting the apparatus.

It is a further object of our invention to provide an improved shakeout apparatus which automatically con trols the movement of the castings from the mold line along the apparatus to the removal position at the end of the apparatus.

These and other objects of our invention are accomplished in accordance with the preferred embodiment by providing a pair of suspended, parallelly spaced, horizontally disposed rails mounted at the end of a continuously traveling row of contiguous, flaskless type sand molds containing cast articles therein and having ends opposite the direction of movement of the molds adapted for piercing each of the oncoming molds carried by the conveyor into engagement with the ends and for supportingly engaging each of the castings. The rails are preferably vibrated in a direction inclined to the horizontal and away from the oncoming molds to facilitate piercing of the molds and to advance the sand-bearing castings to the opposite end of the rails, separating the sand therefrom, where the castings are removed by a programmed mechanical handling device. The rails preferably include a series of mechanical stops responsive to the positions of the castings on the rails to control their movement therealong.

Other objects and advantages of our invention will be apparent from the following detailed description, reference being had to the accompanying drawings of which: I

FIG. 1 is a schematic side elevational view of an automated mold forming and casting process;

FIG. 2 is a schematic cross-sectional side view of the mold forming apparatus shown in FIG. 1;

FIG. 3 is a perspective view of the mold exit and of the mold forming apparatus shown in FIG. 1 with a mold partially broken away; and

FIG. 4 is a perspective view of the apparatus embodying this invention positioned at the end of the casting line as shown in FIG. 1 with a mold partially broken away.

Referring now to the drawings and particularly to FIG. 1, there is shown an automated mold forming and casting process to which our invention is particularly applicable. At the start of the mold line is an automatic mold forming apparatus 10, having a sand delivery bin 12 thereabove, producing flaskless type sand molds 14. As shown in FIG. 2, the molds 14 are formed by compressing foundry sand from a hopper 16 connected to the molding chamber between a tiltable front pattern plate 18 and a rear pattern plate 20 mounted on a hydraulic piston 22. After forming of the mold 14 the front pattern plate 18 is stripped from the mold l4 and tilted up to a horizontal position. The rear pattern plate 20 then conveys the mold linearly forward out of the apparatus on a bed 24 in continuation with the mold forming apparatus 10 bringing the mold 14 into contact with the previously formed mold 14' on bed 24. Thereafter, the rear pattern plate pushes the entire line of molds 14 linearly forward a distance equal to the thickness of the mold 14, thus forming a rectilinear line of molds in a continuous mold forming process.

As may be seen from FIGS. 2 and 3, the end surfaces of the molds carry impressions of the pattern such that mold cavities 26 are formed between the molds when closed with each other. In accordance with conventional foundry practice the mold cavity includes a downsprue 28 and runners 30 communicating with the article forming cavity 32.

As each mold is formed, the mold line is pushed forward on the bed 24 and at a given position along the line the mold cavities 26 of the molds 14 are sequentially filled with molten metal from a bottom pour ladle 34 positioned above the molds 14. After pouring, the molds are pushed onto a continuously linearly traveling conveyor 36 in direct continuation with the bed 24 which is electrically driven in synchronization with the hydraulic piston 22. The molds cool while traveling on the conveyor 36 to form solidified cast articles therein. Mounted in a stationary position at the end of the conveyor is the vibratory shakeout apparatus 38 embodying this invention, which is followed on the mold line by a mechanical handling device 40, as hereinafter more fully explained.

' Referring now to FIG. 4, the vibratory shakeout apparatus 38 includes a pair of suspended, substantially parallelly spaced, horizontally disposed rails 42 having ends 44 extending in a direction opposite the linear path of movement of the molds 14 on the continuously traveling conveyor 36. Below the rails 42 and connected thereto by means of bars 46 and 48, is a motor 50 for vibrating the rails. In accordance with the present invention the rails 42 are continuously vibrated in a direction inclined to the horizontal and away from the oncoming molds, as shown by the arrow 52 in FIG. 4. It will be recognized that our invention is not limited to any particular vibrating means, its position in relation to the rails, or manner of connection with the rails. We have found that an electro-mechanical natural frequency vibratory feeder drive motor having a stroke infinitely variable from zero to five-sixteenths inch is a suitable drive means. When separating ductile iron castings from sand molds having a green strength of about 22 psi and a hot strength over 75 psi, the rails are preferably vibrated at an angle 60 inclined to the horizontal with a 5/16 inch stroke away from the oncoming molds; however, these parameters may be varied depending on the metal being cast, the type of sand used and its adherency to the castings, and the desired speed of movement of the castings along the rails. For example, at lower angles of attack such as 45, the castings move at a greater rate along the rails than at a 60 angle of attack.

Positioned along the rails and on the sides thereof are a primary stop mechanism 54 and a secondary stop mechanism 56 used to control the movement of the castings along the rails 42. Mounted at the ends of the rails 42 opposite ends 44 is a holder 58 for holding the castings for pick-up by the mechanical handling device In operation, the filled molds 14 travel along conveyor 36 in a linear path toward the shakeout apparatus 38 in a continuous mold forming and casting process. At the start of the shakeout operation when the apparatus is free of castings the primary stop 54 is open, i.e., in its down position, and the secondary stop is closed, i.e., in its up position, as shown in FIG. 4. As the molds 14 are carried into the apparatus, the ends 44 of the vibrating rails pierce the molds in a forward and upward direction breaking up the sand molds thereby. When the mold has advanced sufficiently, the ends 44 supportingly engage the cast article 37 at spaced, horizontally disposed portions 60 whereby the cast article 37 becomes suspended on the rails by portions 60. The particular portion of the cast article engaged by ends 44 is not critical, and it may comprise either a portion of the usable casting itself or the gating system may be so designed to provide spaced, horizontally disposed cast arms for engagement by the rails. Since it is often desirable to prevent contact of the rails with the usable cast portion or since intricate castings may not include suitable engaging sections, the latter method is preferred.

Once supported on the rails 42, the cast article advances toward the holder 58 as a result of the vibratory motion of the rails with the sand adhering to the cast article being removed by vibration. The sand removed from the vibrating castings and that broken free on initial piercing of the molds falls below the apparatus into bins, a chute, or onto a conveyor (not shown) for collection and reuse. The primary stop 54 remains open and the secondary stop 56 closed until the first casting contacts the secondary stop 56. The primary stop 54 then closes and the secondary stop 56 then opens, providing the holder 58 is empty. The cast article 37 then advances into the holder 58 where it is removed from the apparatus 38 by a programmed mechanical handling device 40 and transferred automatically for subsequent processing. For example, the cast article may be immediately transferred to apparatus for removing the gating system from the usable cast portion.

As one cast article moves along the rails toward the holder 58, the piercing ends 44 of the rails 42 engage the casting in the following mold in a continuous, sequential shakeout operation such that there is a continuous flow of castings along the rails 42 from the piercing ends 44 to the holder 58, as illustrated in FIG. 4. It will be recognized that the particular sequence of movement of the castings along the rails may be adapted to particular operations. For example, several castings may be backed-up behind the secondary stop 56 before the primary stop 54 closes after which the secondary stop 56 opens allowing only the casting in contact therewith to advance into the holder 58. Further, the primary stop 54 may be operatively connected to the conveyor drive motor. to temporarily stop movement of the molds to allow for clearing of the shakeout apparatus should an excessive number of castings be suspended behind the primary stop.

One of the features of our invention is the ability to remove the cast articles from the molds, separate the sand therefrom, and advance the cast articles to a position for removal by a programmed device in an oriented position. That is, in an automated operation it is highly desirable that the cast articles move in an oriented rather than random fashion whereby the articles may be automatically transferred to successive operations comprising devices designated to accept the articles in a predetermined orientation. As may be seen from FIG. 4, the vibrating rails 42 engage the cast article 37 at portions 60 and separate the sand therefrom thus supporting the cast article in the same orientation as within the mold. As the cast article 37 advances along the rails 42 and into the holder 58 its orientation remains the same. Accordingly, the cast article may be removed from the holder 58 by the mechanical handling device 40 programmed to grasp the castingsin its given orientation.

Although our invention has been described in terms of certain preferred embodiments, it will be recognized by those skilled in the art that other forms may be adopted within the scope of the invention.

We claim:

1. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising at least one suspended, substantially horizontally disposed rail mounted at the end of said row along said linear path, the end of said rail opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said end and for supportingly engaging each of said cast articles, and means for vibrating said rail in a direction inclined to the horizontal to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing end of said rail to the opposite end thereof and to separate the sand therefrom.

2. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, and means for vibrating said rails in a direction inclined to the horizontal to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof and to separate the sand therefrom.

3. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, and means for vibrating said rails in a direction inclined to the horizontal and away from the oncoming molds to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof and to separate the sand therefrom.

4. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, and means for vibrating said rails in a direction inclined to the horizontal to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof in an orientation substantially the same as within the molds and to separate the sand therefrom, the ends of said rails opposite the piercing ends being adapted to receive and hold the cast articles in an orientation substantially the same as within the molds.

5. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, and means for vibrating said rails in a direction inclined to the horizontal and away from the oncoming molds to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof in an orientation substantially the same as within the molds and to separate the sand therefrom, the ends of said rails opposite the piercing ends being adapted to receive and hold the cast articles in an orientation substantially the same as within the molds.

6. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for sequentially separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, the ends of said rails opposite the piercing ends being adapted to receive and hold said cast articles; means for vibrating said rails in a direction inclined to the horizontal to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof and to separate the sand therefrom; and means for stopping the advance of said cast articles along said rails and for sequentially releasing each of said cast articles in contact therewith for advance to said ends adapted to hold said cast articles when said ends are free of cast articles.

7. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, and means for vibrating said rails in a direction 45 to 60 inclined to the horizontal to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof and to separate the sand therefrom.

a a: a s a

Claims

7. In combination with a row of contiguous, flaskless type sand molds containing cast articles therein mounted on a continuously traveling conveyor adapted for movement along a linear path, apparatus for separating said cast articles from said molds comprising a pair of suspended, substantially parallelly spaced, horizontally disposed rails mounted at the end of said row along said linear path, the ends of said rails opposite the direction of movement of said row being adapted for piercing each of said molds as each mold is carried by said conveyor into engagement with said ends and for supportingly engaging each of said cast articles, and means for vibrating said rails in a direction 45* to 60* inclined to the horizontal to facilitate piercing of said molds and to advance the sand-bearing cast articles from the piercing ends of said rails to the opposite end thereof and to separate the sand therefrom.