WO2016166577A2 - Agencement pour remplir simultanément des première et seconde cavités de moule et son procédé - Google Patents

Agencement pour remplir simultanément des première et seconde cavités de moule et son procédé Download PDF

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Publication number
WO2016166577A2
WO2016166577A2 PCT/IB2015/052815 IB2015052815W WO2016166577A2 WO 2016166577 A2 WO2016166577 A2 WO 2016166577A2 IB 2015052815 W IB2015052815 W IB 2015052815W WO 2016166577 A2 WO2016166577 A2 WO 2016166577A2
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WO
WIPO (PCT)
Prior art keywords
molten metal
rocker body
primary stream
curved surface
pouring
Prior art date
Application number
PCT/IB2015/052815
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English (en)
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WO2016166577A3 (fr
Inventor
Kaj Jørgen JENSEN
Original Assignee
Disa Industries A/S
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Disa Industries A/S filed Critical Disa Industries A/S
Priority to PCT/IB2015/052815 priority Critical patent/WO2016166577A2/fr
Publication of WO2016166577A2 publication Critical patent/WO2016166577A2/fr
Publication of WO2016166577A3 publication Critical patent/WO2016166577A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00—Casting plants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D35/00—Equipment for conveying molten metal into beds or moulds
    • B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D37/00—Controlling or regulating the pouring of molten metal from a casting melt-holding vessel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D39/00—Equipment for supplying molten metal in rations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D47/00—Casting plants
    • B22D47/02—Casting plants for both moulding and casting

Definitions

  • the present invention concerns an arrangement for simultaneously pouring first and second mould cavities in a mould string, such as in a green sand metal foundry, and a method therefor.
  • the mould string is stationary for the time needed to produce two moulds, accordingly leaving a signifi- cantly longer time for pouring, and first when the two moulds have been produced is the mould string advanced. Accordingly there arises a need to be able to pour two moulds at the same time.
  • WO2005056214 On example of a technique for pouring molten metal into more than one mould cavity at the same time is described in WO2005056214, in which green sand moulds are formed so as to include runners in the moulds, resulting in that every two mould cavities formed by the moulds in the mould line are fluidly connected, such that both mould cavities can be filled with molten metal simultaneously by pouring molten metal into only one of the mould cavi- ties.
  • WO2013003359 Another way of achieving pouring of metal into more than one mould cavity at the same time is described in WO2013003359, which discloses a pouring machine or pouring unit which has a molten metal holding and pouring box with dual pouring nozzles. Each of the pouring nozzles may be selectively opened or closed to pour the molten metal by its own stopper rod.
  • mould thickness is often changed when pattern is changed, i.e. when changing from one part to another. This is important as foundries need to be flexible, i.e. be able to change pattern fast according to the just-in-time principle.
  • At least one of the above objects, or at least one of any of the further objects which will be evident from the below description, are according to corresponding first and second aspects of the present invention achieved by the arrangement according to claim 1 and the method according to claim 13.
  • a single primary stream of molten metal such as supplied from a conventional pouring unit utilizing a single conventional stopper rod, is simply divided into two secondary streams and used to fill two mould cavities simultaneously.
  • the rocker body divides the primary stream of molten metal into two secondary streams of molten metal without needing any additional stopper rods or pouring nozzles that will lead to extra main- tenance.
  • Simple pivoting of the rocker body makes it possible to ensure an equal filling of both mould cavities and pivoting of the rocker body. i.e. adjusting the flow rate ratio (kg molten metal per second) of the first secondary stream to the second secondary stream, does not involve contact with the molten metal as compared to the prior art dual nozzle - dual stopper devices. Further the rocker body may be manufactured with less tolerance and of cheaper materials than pouring nozzles and stopper rods, as it is a simple part.
  • both mould cavities can be filled at the same time.
  • the rocker body is supplied with molten metal in a single stream.
  • a standard molten metal holding box or tundish equipped with a single pouring nozzle and a single stopper, may be used to supply the molten metal for pouring both mould cavities. This makes the arrangement simple when compared to the prior art solution.
  • the term "mould cavity” refers to a shaped cavity which gives a definite shape to molten metal introduced into it. Once the molten metal has solidified, its solidified shape is determined by the mould cavity.
  • the first and second mould cavities may be formed in first and second moulds in the mould string, however it is preferred that the first and second mould cavities are defined between adjacent moulds in the mould string, such as in a mould string produced by a vertical flask- less green sand moulding machine.
  • the moulds poured may alternatively be a number of moulds away from each other.
  • the first and second mould cavities to be poured may comprise, or be fluidly connected to, corresponding first and second pouring cups and further downsprues or channels, into or through which molten metal is introduced or flows, in the moulds or defined between moulds in the mould string.
  • first and second mould cavities is to be un- derstood as encompassing pouring molten metal into first and second cavities.
  • the mould string may be an array of adjacent moulds, each mould comprising a mould cav- ity, an array of moulds, each mould comprising two mould parts defining a mould cavity, or alternatively an array of adjacent moulds, each two adjacent moulds defining a mould cavity between them.
  • the source of molten metal may be any device capable of delivering a controlled flow of molten metal, such as a molten metal holding and pouring box of a pouring unit. Alterna- tively the source of molten metal may be a tundish or a ladle.
  • the rocker body is preferably shaped as a semicylinder of a refractory material.
  • the semi cylinder is preferably right cylindrical, i.e. having a constant radius and an axis orthogonal to the radius; however, the semi cylinder may be elliptically cylindrical, i.e. with a radius that varies along the arc.
  • the curved surface is devoid of sharp edges which can disturb the flow of molten metal on the curved surface.
  • the rocker body is preferably made from known refractory materials.
  • the choice of refrac- tory material depends on the type of metal, the temperature of the molten metal in the pri- mary stream of molten metal, and the desired lifetime.
  • rocker body is preferably arranged below the source of molten metal so that the primary stream of metal pours down onto the rocker body.
  • curved surface is to be understood as encompass- ing convex upper surface.
  • the curved surface is preferably as described above a semicylindrical surface having its highest point along a centreline and curving down towards the first and second end por- tions.
  • the curved surface is preferably rectangular.
  • the curved surface may however also be the inner surface of a cylinder or channel.
  • the rocker body may be shaped like a prism.
  • curved is not to be limited to the meaning of smoothly or continuously curved. Rather curved is to be understood as encompassing sur- faces which change orientation in discrete steps, such as the surface of a prism or a halved polygonal cylinder.
  • the primary stream of molten metal is preferably received in the centre of the curved sur- face between the first and second end portions.
  • the primary stream of molten metal is pref- erably received on the highest point of the curved surface or above said pivot axis.
  • the primary stream of molten metal is divided into the first and second secondary stream by the force of gravity and by the inertia of the molten metal in combination with the shape of the curved surface.
  • the opposite first and second end portions can be straight edges, but may alternatively be curved so as to concentrate or funnel the first and second secondary streams of molten metal, i.e. by decreasing the width of the first and second secondary streams of molten metal in relation to the length of the first and second end portions. This may be advanta- geous where the opening of the mould cavity, i.e. the pouring cup into which the first and second secondary stream of molten metal is to be poured, is narrow.
  • the first and second secondary streams of molten metal preferably pour down into the first and second mould cavities from the first and second end portions.
  • the rocker body is preferably arranged above the mould string and adapted so that the first end portion is positioned above the first mould cavity, and the second end portion is positioned above the second mould cavity.
  • the rocker body may be pivotable, for example by being mounted or arranged on a rocker body axle, by being attached to a rotating surface, by being attached or positioned on a tiltable surface, etc. If used with a rocker body axle, the rocker body should comprise a bore.
  • the position of the pivot axis in relation to the curved surface and/or the shape of the curved surface may be adapted such that pivoting of said rocker body affects the flow rate ratio of the first secondary stream of molten metal to the second secondary stream of mol- ten metal by positioning the pivot axle in relation to the curved surface, and/or by shaping the curved surface, such that pivoting of the rocker body changes the impact angle between the primary stream of molten metal and the curved surface at the point of impact of the pri- mary stream of molten metal on the upper curved surface.
  • the flow rate (kg/s) ratio of the first and second secondary streams of molten metal is the ratio between the flow rate (kg/s) of the two secondary streams of molten metal.
  • the primary stream of molten metal is preferably delivered in a metered portion.
  • the pivoting of the rocker body is preferably performed concurrent with the delivering of the primary stream of molten metal, but may alternatively be performed after the delivering of the primary stream of molten metal.
  • the primary stream of molten metal may be delivered as discrete portions of molten metal, whereby the pivoting of the rocker body may be performed in the pauses between delivering such discrete portions.
  • the pivoting of the rocker body may be performed manually, or as advantageously embod- ied by the arrangement and the method according to the corresponding first and second aspects of the present invention defined in claims 2 and 12. by a control system.
  • a control system By using the control system, it is ensured that the levels of molten metal in the mould cavi- ties, in particular the pouring cups, are kept at the same predetermined level during pouring, such that pouring of both mould cavities can be completed at the same time, thus keeping the time for pouring of the mould cavities at a minimum.
  • the need for changing the flow rate ratio of the first and second secondary streams of mol- ten metal arises because the flow rate may vary due to presence of slags in the molten metal or other phenomena resulting in the first and second secondary streams of molten metal having non-balanced, i.e. different, flow rates.
  • Techniques for configuring the control system are known to, and can be selected and im- plemented by, the skilled person.
  • the first and second sensors are preferably laser distance sensors using a laser beam to measure a distance.
  • the first and second sensors may be carried by the source of molten metal.
  • the first and second levels of molten metal may be determined by measuring the distance from the respective one of the first and second sensors to the surface of the mol- ten metal, or by measuring the distance from the top of the mould to the first and second levels of molten metal.
  • the first and second sensors may comprise video cameras, ultra sound trans- ceivers, or other types of distance sensors.
  • "determining a level of molten metal is to be under- stood as encompassing determining an amount of molten metal or determining a fill per- centage of molten metal.
  • the pivoting device may for example comprise a rocker body axle, onto which the rocker body is mounted along the pivoting axis, and a motor, such as a step motor, for rotating the rocker body axle, optionally via one or more gears.
  • a pneumatic or hydraulic actuator, or any other actuator device may be used to pivot the rocker body axle.
  • the control device may comprise a computer or comparator circuit.
  • the control device may be connected to, or comprise, a relay circuit for energising the motor, or a valve for control- ling the hydraulic or pneumatic cylinder, or a device for activating any other actuator device.
  • the control device may be set up with the direction of pivoting being correlated to the differ- ence, or the sign positive/negative, of the difference, between the first and second levels of molten metal and the predetermined level.
  • pivoting the rocker body so as to keep the first and second levels at the predetermined level' is to be understood as encompassing pivoting the rocker body so as to equalize the first and second levels, and pivoting the rocker body so as to increase the flow rate of the one of the first and second secondary stream of molten metal pouring into the one of the first and second mould cavities having the lowest level of molten metal in the mould cavity or in the pouring cup fluid ly connected to that mould cavity.
  • Determining the first and second levels is preferably performed continuously during pouring. However, determining the first and second levels may also be performed at discrete times during the pouring, such as at the beginning, midpoint, and end of pouring.
  • the preferred embodiments of the arrangement and method according to the corresponding first and second aspects of the present invention as defined in claims 3 and 15 are advan- tageous as they provide the fastest filling, i.e. pouring, of the mould cavities.
  • the predetermined level may be below the level of the top surface of the moulds, such as for example 1 -20 mm, more preferably 1-10 mm, below the level of the top surface of the moulds.
  • the embodiments of the anrangement and the method according to the corresponding first and second aspects of the present invention defined in claims 4 and 16 are advantageous in that they utilize the first and second sensors to also provide measurements for the control of the primary stream of molten metal. Thus, there is no need for additional sensors to con- trol the primary stream of molten metal.
  • the flow device may for example comprise a stopper rod or a gate valve and an actuator for moving, such as to open or close the stopper rod and the gate valve.
  • the flow de- vice comprises a hydraulic cylinder and a stopper rod connected to the hydraulic cylinder for movement in relation to a pouring nozzle.
  • the control device may be adapted by comprising a comparator circuit or program module for comparing the first and second levels to the predetermined level.
  • the predetermined level is preferably set by an operator, but may alternatively be set by measuring the appar- ent level of the upper surface of the moulds in the mould string using one or both first and second sensors.
  • each sensor projects a beam parallel to the first and second sec- ondary streams of molten metal as the secondary streams of molten metal pour from rocker body down into the moulds.
  • these streams will eventually intersect the beams from the first and second sensors for interfering with the determining of the first and second levels. This can be used by the control device to determine that the amount of mol- ten metal on the rocker body is too high, thus requiring that the primary stream of molten metal is decreased.
  • the embodiments of the arrangement and the method according to the corresponding first and second aspects of the present invention as defined in claims 5 and 15 are advanta- geous as they allow increased yield by lowering the amount of metal that has to be remelted.
  • a portion of the molten metal solidifies in the pouring cup.
  • the pouring cup should be filled up to the level of the upper surface of the moulds to ensure the highest fill rate of the moulds. This however leads to a bigger amount of metal solidifying in the pouring cups, which metal must subsequently be remelted, a process which requires energy.
  • first and second levels at the predetermined level, preferably at the level of the upper surface of the moulds during the initial major period of time of the pouring of the first and second moulds, a high fill rate is achieved for the major part of the pouring. Then, by ending the pouring by keeping the first and second levels at the lower predetermined level, it is ensured that the amount of metal needing to be remelted is minimized.
  • the first and second levels may be kept at the predetermined level until about 80% of the molten metal is delivered, whereafter the first and second levels are allowed to fall to the further predetermined level for delivering the last 20% of the molten metal.
  • the further predetermined level may for example be at the lower third or half of the pouring cup or lower. This method can be used when the castings/feeders are not too close to the top of the mould.
  • the further predetermined level can be higher than the predetermined level. This is advantageous when the castings/feeders are too close to the top of the mould be- cause it may ensure that the feeders/risers are sufficiently filled with molten metal so that sufficient molten metal may be provided to the casting as the casting cools down and solidi- fies, and thereby shrink.
  • the supply sensor may comprise a distance sensor or a camera for measuring the amount, such as the thickness and/or width of the primary stream of molten metal at the point where it is received by the curved surface of the rocker body, or for measuring the thickness and/or width of the first and second secondary streams of molten metal on the curved sur- face or at the first and second end portions.
  • the amount corresponding to an overflow may be determined empirically by performing tests at different flow rates, noting which amount results in an overflow, this amount being the maximum amount. If the amount is above the maximum amount, the amount is too much and indicates an overflow If the amount is too far below the maximum amount, such as below 50% of the maximum amount, the amount is less than the rocker body can handle.
  • An overflow of the curved surface may comprise molten metal pouring from other parts of the curved surface than the first and second end portions.
  • the embodiment of the arrangement according to the first aspect of the present invention defined in claims 7 is advantageous in that it increases the capacity of the rocker body and reduces spilling of molten metal from the rocker body.
  • the first and second ridges are preferably straight.
  • the first and second ridges prevent or limit any flow of molten metal not directed towards the first or second end portions.
  • the embodiment of the arrangement according to the first aspect of the present invention defined in claims 8 is advantageous as it provides a more direct division of the primary flow of molten metal.
  • the central ridge extends above the curved surface, it moves primarily horizontally, by being further away from the pivot axis, during limited pivoting of the rocker body. Instead of relying on the impact angel between the primary stream of molten metal and the curved surface, the central ridge moves at a right angle to the transversal cross section of the primary stream of molten metal. Accordingly, for a given angle that the rocker body is pivoted, the central ridge causes a larger difference in volume ratio between the first and second secondary streams of molten metal.
  • the embodiment of the arrangement according to the first aspect of the present invention defined in claims 9 is advantageous in that it increases the capacity of the rocker body as well as directs the first and second secondary streams of molten metal to the first and sec- ond end portions and into the first and second mould cavities.
  • the depth and width of the groove determine the maximum flow rate that can be handled by the groove.
  • the at least one groove preferably runs in a straight line along the curved surface.
  • the curved surface comprises several parallel grooves.
  • the embodiment of the arrangement according to the first aspect of the present invention defined in claims 10 is advantageous to use when pouring moulds capable of handling dif- ferent flow rates in kg molten metal per second. Simply moving the rocker body allows the selection of the groove which is to receive the primary stream of molten metal and which is suitable for handling the flow rate of the primary stream of molten metal.
  • the first groove imparts a first cross section to the first and second secondary streams of molten metal where the first and second secondary streams of molten metal leave the rocker body.
  • the second groove imparts a second, larger cross section to the first and second secondary streams of molten metal where the first and second secondary streams of molten metal leave the rocker body.
  • the first and second grooves are configured so that the distance between the centres of these cross sections are the same for both grooves. This corresponds to the mould thickness being the same for both grooves.
  • the embodiment of the arrangement according to the first aspect of the present invention defined in claim 11 is advantageous as it allows quick changes of mould thickness by sim- ply moving the rocker body axially along the pivot axis and thereby selecting which of the first and second grooves is to receive the primary stream of molten metal.
  • the first groove imparts a first cross section to the first and second secondary streams of molten metal where the first and second secondary streams of molten metal leave the rocker body.
  • the second groove imparts a second cross section to the first and second secon- dary streams of molten metal where the first and second secondary streams of molten metal leave the rocker body.
  • the first and second grooves are configured so that the first and second cross sections are the same, the first and second groves further being configured such that the distance between the centres of these cross sections differs be- tween the grooves. This corresponds to the mould thickness being different for the grooves.
  • the embodiment of the arrangement according to the first aspect of the present invention as defined in claim 12 is advantageous as it gives better control over the molten metal and as it prevents splashing off of molten metal from the rocker body.
  • Fig. 1 shows, in perspective view, an overview of parts of a metal foundry including a vertical green sand moulding machine, a mould conveyor carrying a mould string, and a pouring unit comprising a first embodiment of an arrangement for simultaneously pouring two moulds according to the first aspect of the present invention
  • FIG. 2 shows, in cross section, a first embodiment of the arrangement for simultane- ously pouring two moulds according to the first aspect of the present invention, the first em- bodiment comprising a molten metal holding and pouring box and a first embodiment of a rocker body
  • Fig. 3 shows, in perspective view, the first, a second, a third, a fourth, and a fifth em- bodiment of a rocker body.
  • one or more 'signs added to a reference number indicates that the element referred to has the same or similar function as the element designated the refer- ence number without the 'sign, however, differing in structure.
  • Fig. 1 shows, in perspective view, a highly schematic overview of parts of a metal foundry 2 in which casting of molten metal 4 is performed.
  • the metal foundry 2 comprises a vertical green sand moulding machine 10 which is connected to a mould conveyor 12 which carries and conveys a mould string 14 made up from the individual moulds, one of which is desig- nated the reference numeral 20. which are produced by the vertical green sand moulding machine 10.
  • the metal foundry 2 further comprises a pouring unit 16 for pouring the molten metal 4.
  • the pouring unit 16 further comprises a first embodiment 30 of an arrangement according to the first aspect of the present invention, shown in detail in fig. 2.
  • the vertical green sand moulding machine 10 compresses green sand between two pattern plates to form moulds 20. which moulds 20 are then each ejected from the verti- cal green sand moulding machine 10 and added to the mould string 14 on the moulding conveyor 12. The moulds 20 are subsequently conveyed to the pouring unit 16. which pours the molten metal 4 into the mould cavities of the moulds 20.
  • the metal foundry 2 operates using the principle described in EP1326726, or a similar principle, according to which prin- ciple the mould string 14 is transported two moulds at a time in order to provide a longer continuous pouring time. This however requires that two moulds 20 must be poured at the same time while the mould string 14 is stationary.
  • Fig. 2 shows, in cross section, a first embodiment 30 of the arrangement according to the first aspect of the present invention, the first embodiment 30 comprising a molten metal holding and pouring box 40 positioned above the mould string 14 and forming a part of the pouring unit 16 in fig. 1 , and a first embodiment of a rocker body 60.
  • the molten metal holding and pouring box 40 comprises a sidewall 42 and a bottom 44 defining a reservoir 46 for holding the molten metal 4.
  • Part of the bottom 44 defines a pouring nozzle 48. through which the molten metal 4 may be selectively poured.
  • a stopper rod 50 is disposed within the reservoir 46 and is displaceable up and down by a stopper actuator such as a hydraulic cylinder 114 or a electric gear mechanism (not shown) as is known in the art, for selectively causing the tip 52 of the stopper rod 50 to enter the pouring nozzle 48 for closing and opening the pouring nozzle 48.
  • a stopper actuator such as a hydraulic cylinder 114 or a electric gear mechanism (not shown) as is known in the art, for selectively causing the tip 52 of the stopper rod 50 to enter the pouring nozzle 48 for closing and opening the pouring nozzle 48.
  • the molten metal holding and pouring box 40 is supplied with molten metal from the main body of the pouring unit 16, which pouring unit is regularly filled up with molten metal from a ladle (not shown).
  • the rocker body 60 is arranged beneath the pouring nozzle 48.
  • the rocker body 60 com- prises a curved surface 62 for receiving a primary stream of molten metal 4' pouring from the pouring nozzle 48 of the molten metal holding and pouring box 40.
  • the rocker body 60 further comprises first and second opposite end portions 64 and 66. As the primary stream of molten metal 4' is poured down onto the curved surface 62, it is divided into first and sec- ond secondary streams 4" and 4"'.
  • the rocker body 60 has a generally semi-circular cross section with opposite semi-circular end faces, one of which is designated the reference numeral 68.
  • the rocker body 60 advantageously, as shown in fig. 3A, comprises opposite ridges 70 and 72 above the semicircular end surfaces 68, the ridges 70 and 72 being orthogonal to the first and second end portions 64 and 66.
  • the rocker body 60 comprises a groove 74 formed in the curved surface 62, the groove 74 running parallel to the ridges 70 and 72 and orthogonally to the first and second end portions 64 and 66 for receiving the primary stream of molten metal 4' and directing the first and second secondary stream of molten metal 4" and 4"' towards the first and second end portions 64 and 66.
  • rocker body 60 comprises a bore 76 for allowing the rocker body 60 to be suspended on an axle as described below with renewed reference to fig. 2.
  • the rocker body 60 is pivotably arranged on a rocker body axle 80.
  • the rocker body axle 80 is preferably attached to the molten metal holding and pouring box 40, or may alternatively be attached to its own support structure, or to another part of the pour- ing unit 16, and positioned between the molten metal holding and pouring box 40 and the mould string 14.
  • the rocker body 60 once arranged on the rocker body axle 80, may be pivoted manually in order to affect the volume ratio of the first secondary stream of molten metal 4" to the second secondary stream of molten metal 4"', the arrangement 30 advantageously further comprises a control system 90.
  • the control system 90 comprises an electric step motor 92 which is connected to the rocker body axle 80 via drive gear 94 and rocker body axle gear 96.
  • the control system further comprises first and second laser distance sensors 98 and 100, emitting first and second laser beams 102 and 104, and third and fourth laser distance sensors 106 and 108, emitting third and fourth laser beams 1 10 and 112.
  • a com- puter 120 receives the distance information from the first and second laser distance sensors 98 and 100 and for actuating the step motor 92 for pivoting the rocker body 60 as will be described further below.
  • the computer 120 further receives the distance information from the third and fourth laser distance sensors 106 and 108, the distance information corresponding to the amount of molten metal on the rocker body 60.
  • an electric step motor 92 is shown in fig. 2. a hydraulic or other type of actuator could also be used.
  • the first embodiment 30 of the arrangement according to the first aspect of the present in- vention is arranged above the mould string 14.
  • the mould string is made up from moulds 20 as shown in fig. 1.
  • Fig. 2 in particular refers to the individual moulds 20, 20,, 20 2 ,20 3 . 20 tone, and 20 5 .
  • Each of the moulds 20, 20,, 20 2 , 20 3 , 20 4 , and 20 5 defines, together with the one of the moulds 20, 20-,. 20 ? ,20 3 .
  • the moulds 20 are poured by providing the mould cavi- ties with the molten metal 4.
  • Each mould cavity 22, 22,, 22 2 , 22 3 , 22 4 defines the shape of the object that is to be cast of the molten metal 4 and the mould 20.
  • Each mould 20, 20,, 20 ? . 20 3 , 20 4 . and 20 6 further, together with the adjacent one of the moulds 20, 20,, 20 2 . 20 3 , 20 4 , and 20 5 , defines a pouring cup 24, 24,, 24 ? , 24 3 , 24 4 which is open to the top surface of the moulds 20 and into which the molten metal 4 is poured as the secondary streams of molten metal 4" and 4"'.
  • Downsprues 26. 26,, 26 2 , 26 3 , 26 4 defined by the moulds 20. 20,, 20 2 , 20s, 20 4 . and 20 s fluidly connect the pouring cups 24. 24,, 24 2 .
  • the first embodiment 30 of the arrangement according to the first aspect of the present invention allows two mould cavities, i.e. 22, and 22 2 , to be filled at the same time, yet it requires only a single stopper rod 50.
  • the rocker body 60 may be pro- symbolized from any readily available refractory material and can easily and inexpensively be replaced as needed when worn out from the contact with the molten metal 4'. If needed, the rocker body 60 may be replaced by a rocker body 60 having other dimensions if the thick- ness of the moulds 20 or the flow rate kg/s of molten metal needed in the two secondary streams of molten metal 4" and 4'" is changed at a pattern change.
  • the control system 90 controls the pouring of the molten metal into the pouring cups 24i and 24 ⁇ and thereby controls the pouring of the mould cavities 22i and 22 2 by measuring first and second levels of molten metal in the pouring cups 24, and 24 2 using the first and second laser distance sensors 98 and 100. The measurements are then relayed to the computer 120, which is programmed to compare the first and second levels and energize the step motor 92 for pivoting the rocker body 60 so as to keep the first and second levels at a predetermined level during the pouring. This ensures that both moulds, i.e. mould cavities 22, and 22 2 , are filled simultaneously and at the same rate. Further it ensures that the same filling profile is achieved for each mould 20 poured, thereby providing a stable and repro- ducible quality of the castings produced.
  • this predetermined level is defined by the top surface of the moulds 20, i.e. the highest possible level without the pouring cups 24, and 24 2 overflowing, for achieving the maximum filling rate of the mould cavities 22, and 22 2 , the filling rate being influenced of the height of molten metal in the pouring cups 24, and 24 7 .
  • the computer 120 is further programmed to compare the first and second levels of molten metal in the pouring cups 24, and 24? to the predetermined value, and if the levels of molten metal exceeds the predetermined value, control the hydraulic cylinder 114 to decrease or stop the primary stream of molten metal 4', or if the levels of molten metal fall below the predetermined value, control the hydraulic cylinder 114 to increase the primary stream of molten metal 4'.
  • the computer 120 further uses the distance information from the third and further laser dis- tance sensors 106 and 108 to determined the amount of molten metal on the curved sur- face 62 of the rocker body 60. If this amount becomes too high, which indicates an overflow of the curved surface 62 and the rocker body 60, the computer 120 is programmed to con- trol the hydraulic cylinder 1 14 to decrease or stop the primary stream of molten metal 4'.
  • the inner walls of the bore 76 may advantageously comprise axial splines, ridges or grooves (not shown) for interacting with mating splines, grooves or ridges provided on the rocker body axle 80 for providing a rotation fast connection of rocker body 60 to the rocker body axle 80 with rocker body axle gear 96.
  • the bore 76 may be smooth and a modified rocker body axle gear (not shown), which is pivotable around the rocker body axle 80 and which carries pins (not shown) for engaging holes (not shown) on the end face 68 of the rocker body 60, may be used to pivot the rocker body 60.
  • Fig. 3B shows a second embodiment of the rocker body 60' which differs from the first em- bodiment of the rocker body 60 shown in figs 2 and 3A by having a modified curved surface
  • the central ridge 78 defines a central end portion 82 and assists in dividing the primary stream of molten metal 4' into the first and second secondary streams 4" and 4 " and further increases the effect that pivoting the rocker body 60' has on the flow rate ratio of the first secondary stream of molten metal 4" to the second secondary stream of molten metal 4"".
  • the ridges 70 and 72 may comprise first and second central ridge portions 71 and 73 flanking the central ridge 78.
  • the bore 76 corresponding to the axis around which the rocker body 60 pivots, is placed close to or at the centre of gravity of the rocker body 60.
  • the position of the bore 76 in relation to the radius of the curved surface 62 at the centre of the curved surface 62, i.e. where the primary stream of molten metal 4' im- pacts the curved surface 62, should be chosen such that the impact angle between the pri- mary stream of molten metal 4' and the centre of the curved surface 62 changes when the rocker body 62 is pivoted. This may for example be achieved as shown in fig. 2 and 3A by ensuring that the distance between the bore 76 and the centre of the curved surface 62 is smaller than the radius of at least the centre of the curved surface.
  • 3C shows a third embodiment of the rocker body 60" which differs from the rocker body 60 in that a modified curved surface 62" forms a branching channel 74", which is a modifi- cation of the groove 74, within the rocker body 60".
  • the branching channel 74' has an inlet aperture 84 for receiving the primary stream of molten metal 4' and directs the first and sec- ond secondary streams 4" and 4"' of molten metal to first and second end portions 64' and 66', which are modifications of the first and second end portions 64 and 66 of the rocker body 60.
  • the rocker body 60" is advantageous as it gives good control over the molten metal. Fur- ther it prevents splashing of the molten metal, and it insulates and prevents contamination of the first and second secondary streams 4" and 4"' of molten metal.
  • Fig. 3D and 3E show a fourth embodiment of the rocker body 60"' which differs from the first embodiment 60 in that a modified curved surface 62"' comprises three grooves 74, 74" and 74'" having different widths and depths for receiving a primary stream of molten metal 4' having different flow rates (kg molten metal per second).
  • the three grooves 74 are shown in that a modified curved surface 62"'.
  • 74" and 74"' extend from modified first and second edge portions 64" and 66" and shape first and second secondary streams of molten metal 4" and 4'" of different cross sectional areas where the first and secondary streams of molten metal 4" and 4'" leave the respective groove 74, 74" and 74"' of the rocker body 60'" to pour down into the pouring cups 24, and 24 2 .
  • the distance A between the centres of the cross sectional areas of the first and second secondary stream of molten metal 4" and 4"' is the same for all three grooves 74, 74" and 74"'. Accordingly the rocker body 60"' is to be used for pouring moulds having a single predetermined mould thickness corresponding to the distance A.
  • Rocker body 60"' is advantageous to use when pouring moulds 20 requiring different flow rates of molten metal.
  • Each of the grooves 74, 74" and 74 " is dimensioned for being used with a specific maximum flow rate.
  • groove 74 is dimensioned for receiving a primary stream of molten metal 4' for instance containing 6 kg molten metal per second
  • groove 74" and 74"' for instance are dimensioned for receiving primary streams of molten metal 4' containing 8 kg molten metal per second and 10 kg molten metal per second, re- spectively.
  • the rocker body 60'" is positioned axially on the rocker body axle 80 such that the primary stream of molten metal 4' is deposited into only one of the grooves 74. 74" and 74" and flows towards the modified end portions 64" and 66". These end portions differ from those of fig 3A and 3B merely due to the grooves 74" and 74'".
  • any one of the groves 74, 74" and 74"' may be se- lected for receiving the primary stream of molten metal 4', thus allowing one and the same rocker body 60'" to be used to pour moulds 20 at different flow rates. Selecting the groove 74.
  • rocker body axle 80 may be fashioned with axially directed splines, and the bore 76', which is modified from the bore 76 by being longer, is provided with corresponding axially directed grooves or ridges for ensuring a rota- tion-fast connection between rocker body and rocker body axle.
  • the stopper 50 must be controlled such that the flow of molten metal 4' is not larger than the grooves 74, 74" and 74'" can handle.
  • FIG. 3F and 3G show a fifth embodiment of the rocker body 60"" which differs from the first embodiment 60 in that a modified curved surface 62"" comprises three grooves 74, 74"" and 74" " having the same widths and depths for receiving a primary streams of molten metal 4' having the same flow rates.
  • the grooves 74, 74"" and 74 extend from modified first and second edge portions 64"' and 64 " and shapes first and second secondary streams of molten metal 4" and 4"' of identical cross sectional areas, where the first and secondary streams of molten metal 4" and 4"' leave the respective groove 74, 74"" and 74'"" of the rocker body 60"" to pour down into the pouring cups 24i and 24?. As seen in fig.
  • the rocker body 60 " is to be used for pouring moulds 20 having varying mould thicknesses using a set flow rate.
  • rocker body 60"" In use the rocker body 60"" is positioned axially on the rocker body axle 80 such that the primary stream of molten metal 4' is deposited into only one of the grooves 74, 74"" and 74""' and flows towards the modified end portions 64'" and 66'".
  • any one of the groves 74. 74"" and 74'"" may be selected for receiving the primary stream of moKen metal 4', thus allowing one and the same rocker body 60"' to be used to pour moulds 20 having different thicknesses.
  • the rocker body axle 80 may be fashioned with axially directed splines, and the bore 76", which is modified from the bore 76 by being longer, is provided with corresponding axially directed grooves or ridges for ensuring a rota- tion-fast connection between rocker body and rocker body axle. To prevent overflow of the grooves 74.
  • the stopper 50 must be controlled such that the flow of molten metal 4' is not larger than the grooves 74 and 74"' and 74""' can handle.
  • Optional ridges 70 and 72 can reduce the consequences of metal overflow.

Abstract

La présente invention concerne un agencement (30) permettant de remplir simultanément des première et seconde cavités de moule (211, 222) dans un aiguillon de moule (14). L'agencement (30) comprend une source de métal fondu (40) pour délivrer un flux primaire de métal fondu (4'), et un corps de culbuteur (60) agencé de manière à recevoir le flux primaire de métal fondu (4') provenant de la source de métal fondu (40). Le corps de culbuteur (60) comprend une surface incurvée (62) pour recevoir le flux primaire de métal fondu (4') et diviser le flux primaire du métal fondu (4') en des premier et second flux secondaires de métal fondu (4", 4"") s'écoulant vers des première et seconde parties d'extrémité opposées (64, 66) de la surface incurvée (62). Les premier et second flux secondaires de métal fondu (4", 4"') se déversent depuis les première et second parties d'extrémité (64, 66) dans les première et seconde cavités de moule (211, 222). Le corps de culbuteur (60) peut en outre pivoter autour d'un axe de pivotement (80), et la position de l'axe de pivotement par rapport à la surface incurvée (62) et/ou la forme de la surface incurvée (62) sont conçues de telle sorte que le pivotement du corps de culbuteur (60) affecte le rapport entre les débits (kg/s) du premier flux secondaire de métal fondu (4") et du second flux secondaire de métal fondu (4"'). L'invention permet ainsi d'obtenir un agencement (30) permettant de remplir simultanément des première et seconde cavités de moule (211, 222) à partir d'une seule source de métal fondu, ledit agencement étant simple et peu complexe. Le corps de culbuteur (60) peut être facilement échangé ou ajusté pour des épaisseurs de moules différentes et des débits différents. De préférence, l'agencement (30) comprend un système de commande (90) pour commander la coulée en faisant pivoter le corps de culbuteur (60) et pour commander le débit dans le flux primaire de métal fondu (4'). L'invention concerne également un procédé permettant de remplir simultanément des première et seconde cavités de moule (211, 222) en utilisant l'agencement (30).
PCT/IB2015/052815 2015-04-17 2015-04-17 Agencement pour remplir simultanément des première et seconde cavités de moule et son procédé WO2016166577A2 (fr)

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Publication number Priority date Publication date Assignee Title
CN108526455A (zh) * 2018-06-06 2018-09-14 仙居县顺安交通设施有限公司 浇注生产线

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US3747808A (en) * 1971-11-12 1973-07-24 Pennwalt Corp Molten metal pouring device having pantograph tilting mechanism
DE2709052C3 (de) * 1976-03-05 1980-12-04 Hachinohe Smelting Co., Ltd. Verfahren und Vorrichtung zum Eingießen vorbestimmter Metallschmelzenmengen in aufeinanderfolgende Kokillen
DK88882A (da) * 1982-03-01 1983-09-03 Dansk Ind Syndikat Anlaeg til fremstilling af stoebegods i en trinvis fremfoert stoebeform bestaaende af ens, kasseloese formparter
AU2003287875A1 (en) * 2003-12-11 2005-06-29 Disa Industries A/S Method and apparatus for pouring several moulds in a mould-string plant in one pouring operation
US7806161B2 (en) * 2006-12-08 2010-10-05 Thyssenkrupp Waupaca Inc. Molding and casting machine
DE102007018008B3 (de) * 2007-04-17 2008-06-12 Sms Meer Gmbh Verfahren und Vorrichtung zum Gießen von Formteilen, insbesondere von Nicht-Eisen-Anoden
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CN108526455A (zh) * 2018-06-06 2018-09-14 仙居县顺安交通设施有限公司 浇注生产线

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