WO2016166578A2 - Procédé et système pour la multi-indexation de coulées - Google Patents

Procédé et système pour la multi-indexation de coulées Download PDF

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Publication number
WO2016166578A2
WO2016166578A2 PCT/IB2015/052821 IB2015052821W WO2016166578A2 WO 2016166578 A2 WO2016166578 A2 WO 2016166578A2 IB 2015052821 W IB2015052821 W IB 2015052821W WO 2016166578 A2 WO2016166578 A2 WO 2016166578A2
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WO
WIPO (PCT)
Prior art keywords
mould
moulds
string
moulding machine
pouring
Prior art date
Application number
PCT/IB2015/052821
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English (en)
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WO2016166578A3 (fr
Inventor
Jørn Erhard JOHANSEN
Per Larsen
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.)
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Publication date
Application filed by Disa Industries A/S filed Critical Disa Industries A/S
Priority to PCT/IB2015/052821 priority Critical patent/WO2016166578A2/fr
Publication of WO2016166578A2 publication Critical patent/WO2016166578A2/fr
Publication of WO2016166578A3 publication Critical patent/WO2016166578A3/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
    • B22D47/02—Casting plants for both moulding and casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C11/00—Moulding machines characterised by the relative arrangement of the parts of same
    • B22C11/10—Moulding machines characterised by the relative arrangement of the parts of same with one or more flasks forming part of the machine, from which only the sand moulds made by compacting are removed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D33/00—Equipment for handling moulds
    • B22D33/005—Transporting flaskless moulds

Definitions

  • the present invention concerns a method and system for multi-indexing moulds whereby the time available in the machine cycle for pouring of the moulds and the production rate of moulds may both be increased. For presently known solutions these are parameters that go against each other. In other words, with the present invention it is possible to gain signifi- cant increases in productivity, up to 17 % more moulds per hour, and at the same time gain significant increases in available pouring time, up to 77 %. Increasing available pouring time is very important as this in many applications is the true limiting factor on productivity, as there is, in practice, a limit on how many kilograms per second that can be poured without increasing scrap due to sand inclusions from erosion of the mould cavity.
  • any solution aimed at increasing production rate must also ensure that sufficient pouring time is obtained, or as for the present invention, increased.
  • An increased available pouring time also, in addition to a production with a low amount of scrap, gives a possibility for improving yield, i.e. less metal needs to be remelted. resulting in cost savings and a lowered impact on the environment through less usage of materials and energy.
  • Increasing productivity is an important way of optimizing production for lower costs.
  • the production rate in a foundry using a flaskless moulding machine as described above is dependent on, on one side, the cycle time of the machine, i.e. the time needed to produce each mould, and on the other side, the time needed to pour the molten metal into the mould.
  • the cycle time of the machine i.e. the time needed to produce each mould
  • the mould string is ad- vanced one step corresponding to the thickness of the mould produced.
  • pouring of the molten metal generally has to stop because, although solutions have been suggested where pouring is performed as the mould string is advanced, these solutions have in practice not been very usable.
  • the available pouring time in the machine cycle is the total cycle time minus the time needed for advancing the mould string.
  • the cycle time of the moulding machine affects the time available for pouring the molten metal.
  • a short cycle time gives a correspondingly short time for pouring, however, where the molten metal must be poured into the mould cavity within a short period of time, the flow rate (kg/s) must be high, thus causing increased risk of turbulence and erosion, which may lead to defective castings due to erosion of the mould cavity by the molten metal. This results in sand inclusions and other casting defects.
  • each mould produced by the flaskless moulding ma- chine is ejected from the moulding machine and added to the mould string at a position in which the mould intersects the movement path of the swing plate.
  • the advancement of the mould string is then performed solely by the transport system simultaneously with the pres- sure plate retracting and the swing plate starting to move towards the position for producing a new mould.
  • EP 1 326 726 One technique for obtaining both a long pouring time and maintaining high production rate is described in EP 1 326 726, in which a first and a second mould are produced and added to the mould string while the mould string is kept stationary, and while two mould cavities are poured simultaneously. Once the first and second moulds have been added to the mould string, pouring is discontinued while the mould string is advanced the distance corre- sponding to the thickness of two moulds in steps. In the first step the mould string is ad- vanced using the pressure plate in cooperation with the transport system, while in the sec- ond step the mould string is advanced the same distance solely by using the transport sys- tem.
  • This technique provides a somewhat increased production rate, as the travel of the pressure plate is reduced, and an improvement of the available pouring time, however the pouring time afforded by the process leaves room for improvement as the mould string is stationary two times during the double cycle, once after moving the mould string the first step using the pressure plate, and once after the transport system has advanced the mould string. Only the second of these two standstills can be used for pouring.
  • 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, is according to corresponding first and second aspects of the present invention achieved by the method according to claim 1 and the system ac- cording to claim 11.
  • the mould string is advanced only after the first plurality of moulds has been produced and added to the mould string. As the mould string is stationary during this time, a long available time for pouring is achieved. This is in contrast to the prior art solutions described above.
  • the first plurality of moulds is typically at least two to four, but can be larger such as 5 or more.
  • the first plurality of moulds When pouring the moulds in the mould string, the first plurality of moulds must be poured simultaneously. Where the first plurality is two, the moulds are double-indexed, i.e. moved forward the distance equal to two mould thicknesses in one movement. Where the first plurality is three the moulds are triple-indexed and so on.
  • the moulds are preferably made from green sand.
  • Each mould comprises a first mould face and a second mould face defining a first partial mould cavity and a second partial mould cavity such that when positioned one after the other in a mould string, the first partial mould cavity and the second partial mould cavity together define the mould cavity.
  • the mould string comprises a plurality of moulds.
  • the moulds in the mould string are preferably identi- cal, however the mould string may contain groups of different moulds if the pattern plates are changed during production
  • the flaskless moulding machine produces moulds by squeezing a mouldable material, pref- erabhy green sand, between pattern plates corresponding to the first and second partial mould cavities.
  • the flaskless moulding machine is a flaskless vertical green sand moulding machine in which the pattern plates are generally vertical for producing moulds which are positionable one after the other in a horizontal direction such that the mould cavi- ties are produced at the vertical parting line between the individual moulds.
  • the pattern plates of the flaskless moulding machine are mounted on squeeze plates.
  • One of the squeeze plates is driven by the pressure piston for squeezing the mouldable material.
  • the other of the squeeze plates is stationary during squeezing, or alternatively assists in squeezing, and is then moved out of the way, preferably by a rotating movement, for allow- ing the pressure piston to push the produced mould out of the moulding machine.
  • the pres- sure piston may be hydraulic or electrical.
  • the other of the squeeze plates may be hydraulically or electrically driven.
  • the flaskless moulding machine may be configured to form a first plurality of moulds by be- ing connected to a control circuit causing the flaskless moulding machine to cyclically per- form the operations of: introducing mouldable material in the moulding chamber of the flaskless moulding machine, squeezing the mouldable material to form the mould, opening the moulding chamber by retracting and swinging one of the pattern plates, i.e. the swin- gable squeeze plate, ejecting the mould from the moulding chamber using the pressure piston, moving to close up, retracting the pressure piston, and closing the moulding cham- ber by moving and swinging down the swingabJe squeeze plate.
  • the mould cavities may comprise, or be fluidly connected to, a pouring cup for receiving the molten metal from the pouring station. This is typically done from the top.
  • Adding a mould to the mould string may comprise pushing the mould against the last mould in the mould string at a certain contact pressure suitable to ensure that the moulds do not separate when molten metal is poured into the mould cavity between them, causing dimen- sion errors on the casting, leading to scrap, and on the other hand is not so big that it causes the moulds to deform.
  • Each mould in the mould string is in contact with two adjacent moulds, except the last mould closest to the flaskless moulding machine.
  • the mould conveyor may be an AMC (Automatic Mould Conveyor) or a PMC (Precision Mould Conveyor) and includes devices such as thrust bars or walking bars for advancing the mould string, which are known to the person skilled within the art of moulding machines, or another system suitable for transporting the mould string.
  • AMC Automatic Mould Conveyor
  • PMC Precision Mould Conveyor
  • the method and systems according to the corresponding first and second aspects of the present invention may further, as defined in claims 2 and 12, comprise pouring of a first number of moulds of the mould string. Pouring of the first number of moulds takes place once the mould string has been advanced the distance. Thus, while the first number of moulds are poured the first plurality of moulds are produced and added to the mould string. In some cases the first number of moulds correspond to the first plurality of moulds which have been produced and added to the mould string, i.e. the first plurality of moulds is poured as soon as they have been added to the mould string and the mould string has been advanced.
  • the method may comprise producing and adding to the mould string a first, a second, a third, a fourth, and a fifth set of two moulds, the addition of each set of two moulds to the mould string being fol- lowed by the advancement of the mould string, before the first set of two moulds reaching the pouring position, thus corresponding to the first number of moulds, and being poured. Then, after the sixth set of two moulds have been produced and added to the mould string, and the mould string has advanced, the second set of two moulds reach the pouring posi- tion, and so on.
  • the moulds are preferably poured simulta- neously, such as substantially simultaneously, and such that the pouring of each of said first plurality of moulds commences at the same time and finishes at the same time.
  • the step of pouring may be performed by a first plurality of pouring units, or alternatively by one or more second pouring units.
  • Each of the first plurality of pouring units typically comprises a metal holding and pouring box having a pouring nozzle and a moveable stopper rod for selectively blocking the nozzle.
  • Each of the second pouring units may comprise pouring unit as described above but having two or more nozzles, and correspondingly two or more stopper rods, connected to the metal holding and pouring box.
  • the embodiments of the method and the system according to the corresponding first and second aspects of the present invention defined in claims 5 and 15 are advantageous as they further decrease the cycle time of the flaskless moulding machine and thereby in- creases the production rate. This is due to the pressure piston having to travel less
  • the cycle time is further decreased because, in the case when the pressure piston of the flask- less moulding machine brings a mould of the first plurality of moulds into contact with the mould string, it may be necessary to decrease the speed of the pressure piston, at least when the mould is close to the mould string and when/if establishing a contact pressure between the mould and the mould string, so as not to damage the mould or the mould string due to shock.
  • the mould conveyor may have a speed, or have a varying speed. as required to prevent such damage without influencing the cycle time of the flask less moulding machine.
  • the at least one mould is moved to the intermediate position by being pushed by the pres- sure piston of the moulding machine.
  • the intermediate position is a position in which the at least one mould is spaced apart from the flaskless moulding machine and the mould string.
  • the first intermediate posi- tion is as close as possible to the flaskless moulding machine, e.g. beneath the swing able squeeze plate of the flaskless moulding machine.
  • the pressure piston has to deliver the mould as close to the flaskless moulding machine as possible to reduce the travel needed by the pressure piston
  • the pressure piston has to move back partly into the moulding chamber of the flaskless moulding machine before the swingable squeeze plate can swing down, and
  • the mould has to be moved away from below the swingable squeeze plate, i.e. the "swing plate", by the mould conveyor before the swingable squeeze plate can swing down. If the intermediate position is too close to the flaskless moulding machine the cycle has to wait for the mould conveyor to move the mould away from below the swingable squeeze plate before it can swing down. If the intermediate position is too far away from the flaskless moulding machine the cycle has to wait for the pressure piston to move away from below the swingable squeeze plate before it can swing down. Accordingly the optimum intermedi- ate position is a position where the mould conveyor moves the mould out making it possible to swing the swingable squeeze plate down at the same time as the pressure piston has moved back enough to also make it possible to swing the swingable squeeze plate down.
  • the above discussion of the intermediate position is also applicable to the preferred position at which the last mould of the first plurality of moulds is added to the mould string in the em- bodiments defined in claims 1-4 and 11-14, i.e. the last mould should preferably be added to the mould string at a position which is the best compromise of i, ii and iii above, i.e. a po- sition beneath the swingable squeeze plate of the flaskless moulding machine.
  • the mould conveyor may comprise moveable mould retainers for clamping the at least one mould laterally, or top and bottom, and for moving the at least one mould.
  • selected moulds of the first plurality of moulds may be added to the mould string as defined in claims 4 and 14. while the remaining moulds of the first plurality of moulds may be added to the mould string as defined in claims 5 and 15. Preferably, however, each of the first plurality of moulds are added to the mould string as defined in claims 4 and 14.
  • the embodiments of the method according to the first aspect of the present invention as defined in claim 6 and 16 are advantageous as they provide the simplest movement of each of the first plurality of moulds.
  • the core setter is required to be able to set cores at the first plurality of positions as the mould string grows towards the flaskless moulding ma- chine as each of the first plurality of moulds is added to the mould string.
  • the cores can be set with higher precision.
  • a core is basically used to be able to produce castings with internal cavities. Further it can serve other purposes for instance being used when the casting has external undercuts which cannot be moulded.
  • an open mould cavity corresponds to a partial mould cavity.
  • the embodiments of the method according to the first aspect of the present invention as defined in claim 7 and 17 are advantageous as they only require a core setter capable of setting cores in a single position.
  • the core setting position is positioned further away from the flaskless moulding machine to reduce the time that the core setter interferes with the operation of the flaskless moulding machine
  • the moveable mould retainers which moved the mould from the intermediate position to the core setting position, move the mould to add it to the mould string after the core(s) has been set.
  • the core setting position and the intermediate position may be the same, although not if optimal production speed is desired. It is further contemplated within the context of the present invention that the core setter may set cores in a "flying fashion", i.e. while the mould is moved from the intermediate position without stopping at a core setting position.
  • the embodiments of the method and the system according to the corresponding first and second aspects of the present invention defined in claims 8 and 18 define a suitable con- figuration of the mould conveyor for advancing the mould string.
  • the transport system may be an AMC-PMC combo as shown in US2005021 1409, a PMC system (walking bars) alone, or an AMC system (thrust bars) alone, or any other suitable transport system.
  • the transport system may comprises two opposed thrust bars or plates which engage the mould string laterally and which pulls the mould string forward for advancing it.
  • the transport system is a PMC system, it may com- prise walking bars which engage the bottom of the moulds for suspending and moving the mould string forward.
  • the moveable mould retainers may comprise two opposed clamping plates for laterally clamping the single mould.
  • the second plurality of moulds is generally a larger number than the first plurality and may include all the moulds in the mould string.
  • the retaining device may comprise a clamp, electrically, hydraulically or pneumatically actu- ated, which engages the top/bottom or the sides of the last mould.
  • the retaining device selectively keeps the mould string stationary by being actuable to ei- ther engage the last mould, or release the last mould.
  • the retaining device may engage further moulds of the mould string.
  • the method and the system according to the corresponding first and second aspects of the present invention may involve a plurality of stationary mould retainers for engaging each of the first plurality of moulds after each mould has been added to the mould string.
  • the embodiments of the method and the system according to the corresponding first and second aspects of the present invention defined in claims 10 and 20 are advantageous as they decrease the time needed for adding the first plurality of moulds to the mould string, yet may prevent damage to the mould string.
  • the high speed is higher than the low speed.
  • the position close to mould string may be a position in which there is still a physical sepa- ration between the mould and the mould string.
  • the high speed and the low speed may be varied as part of a speed profile.
  • Fig. 1 shows a sequence of operations of the flaskless moulding machine, the mould conveyor, and the pouring unit in a first embodiment of the method according to the first aspect of the present invention
  • Fig. 2 shows a sequence of operations of the flaskless moulding machine, the mould conveyor, and the pouring unit in a second embodiment of the method according to the first aspect of the present invention
  • Fig. 3 shows a sequence of operations of the flaskless moulding machine, the mould conveyor, and the pouring unit in a third embodiment of the method according to the first aspect of the present invention
  • Fig. 4A shows the time needed for forming and pouring two moulds using a prior art method in which the mould string is advanced one mould for each mould that is produced by the flaskless moulding machine;
  • Fig. 4B shows the time needed for forming and pouring two moulds using the first em- bodiment of the method according to the first aspect of the present invention
  • Fig. 5 shows an alternative step in the first, second or third embodiment of the method according to the first aspect of the present invention.
  • 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 a sequence of operations of a flaskless moulding machine, in its entirety des- ignated the reference numeral 10, moulds, one of which is the last mould and is designated the reference numeral 2, in a mould string 4 on a mould conveyor, in its entirety designated the reference numeral 20, and a pouring unit indicated by arrows 30 and 30i in a first em- bodiment of the method according to the first aspect of the present invention.
  • the first plurality is 2.
  • the flaskless moulding machine 10 comprises a moulding chamber 12, a swingable squeeze plate 14 and a pressure piston 16 carrying a squeeze plate 18.
  • the squeeze plate 18 carries a first pattern plate 6a, while the swingable squeeze plate carries a second pat- tem plate 6b.
  • the swingable squeeze plate 14 is moveable for opening the moulding chamber 12, as de- scribed further below.
  • the mould conveyor 20 comprises a moveable mould retainer 22 for gripping and moving the mould 2 or any single mould produced by the flaskless moulding machine 10.
  • the mould conveyor 20 further comprises a stationary mould retainer 24 which can be actuated to clamp down and retain the mould 2 in position.
  • the mould conveyor comprises a transport system exemplified by an AMC (Automatic Mould Conveyor) system illustrated by thrust bars 26. which clamps a plurality of moulds 2 in the mould string 4 for advancing the mould string 4.
  • the moveable mould retainers 22 also assist by clamping and moving the last mould 2.
  • fig 1 A is a core setter 40 for setting core(s) 42 in a mould cavity produced by the mould 2.
  • Opr. used as abbreviation for operation.
  • Tig. 1 A Opr. 1
  • sand (not shown) is shot into the moulding chamber 12.
  • the core setter 40 is setting core(s) 42 in the mould cavity.
  • the moveable mould retainers 22 and the stationary mould retainers 24 are actively holding the mould 2, and thereby the mould string 4, in position and preventing it from moving back.
  • the thrust bars 26 of the AMC system are also active holding the mould string in position. Molten metal is poured simultaneously into two mould cavities as indicated by the arrows 30 and 30 1 .
  • Fig. 1 B shows Opr. 2, during which the pressure piston 16 is activated for squeezing the sand between the swingable squeeze plate 14 and the squeeze plate 18 to form a first mould 2i (shown first in fig. 1 D).
  • the swingable squeeze plate 14 can also assist in squeezing the mould.
  • the core setter 40 is starting to move away from the face of the mould 2 after having set the cores 42.
  • the moveable mould retainers 22, the stationary mould retainers 24, and the thrust bars 26 of the AMC system remain active and the pour- ing of the molten metal continues.
  • Fig. 1C shows Opr. 3, during which the swingable squeeze plate 14 starts to move away from the moulding chamber 12 so as to open the moulding chamber 12 for allowing the now produced first mould 2,, shown in fig. 1D, to be ejected from the moulding machine 10.
  • the core setter 40 has cleared the last mould 2 and continues to move out of the way of the swingable squeeze plate 14.
  • the moveable mould retainers 22, the stationary mould retain- ers 24, and the thrust bars 26 of the AMC system remain active, and the pouring of the molten metal continues.
  • Fig. 1 D shows Opr. 4A Long, during which the first mould 2 1 (also designated 6A, is ejected from the flaskless moulding machine 10 by being pushed by the pressure piston 16. At the same time the moveable mould retainers 22 release the last mould 2 and are transported the length of the last mould (2) towards the flaskless moulding machine 10. The thrust bars 26 of the AMC system have released the plurality of moulds of the mould string 4 and travel with the moveable mould retainers 22 towards the flaskless moulding machine 10. The sta- tionary mould retaining device 24 remains active for holding the last mould 2 and thus the mould string 4 stationary. Pouring continues.
  • the moveable mould retainers 22 and the thrust bars 26 may be mechanically coupled to move together.
  • the first mould 2 is pushed by, e.g. under, the swingabte squeeze plate 14.
  • the core setter 40 which is now outside the path of the mould 2 1 , is not shown in figs. 1D - F.
  • Fig. 1F shows Opr. 5 Long, in which the pressure piston 16 is retracted into the flaskless moulding machine 10 into a ready position for forming the second mould 2 2 .
  • the moveable mould retainers 22 and the stationary mould retainers 24 continue gripping their respective moulds 2 1 and 2.
  • the moveable mould retainers 22, by gripping the first mould 2,. prevent that the first mould 2, is pulled away from the mould string 4 by the pressure piston 16 due to the friction between the first pattern plate 6a and the first mould 2, being larger than the friction between the first mould 2 1 and the mould conveyor 20.
  • the thrust bars 26 of the AMC system remain active, and pouring continues.
  • the swingabte squeeze plate 14 swings down and moves in to close the moulding chamber again while the core setter 40 approaches the first mould 2 t for setting the new core(s) 42, in its mould cavity.
  • the core setter 40 when setting the new core ⁇ s) 42, is positioned in a new position in relation to fig. 1A.
  • the moveable mould retainers 22, the stationary mould retainers 24 and the thrust bars 26 of the AMC system remain active for engaging their respective moulds 2 1 and 2 and the mould string 4 while pouring continues.
  • the mould producing procedure starts over with Opr. 1 , i.e.
  • the core setter 40 sets the core(s) 42,.
  • the thrust bars 26 of the AMC system release the mould string 4 and also follow the moveable mould retainers 22 towards the flaskless moulding machine 10.
  • the stationary retaining device 24 remains active for holding the last mould 2 and the mould string 4 sta- tionary. Pouring continues.
  • the core setter 40 which is now outside the path of the mould 2 ? , is not shown in figs 1 K-M.
  • Opr. 5 Short is performed, which differs from operation Opr 5 Long shown in fig. 1 F in that, as the pressure piston 16 is retracted towards the ready position, as in fig. 1 F, the moveable mould retainers 22 and the thrust bars 26 of the AMC system advance the mould string 4 by gripping and advancing the second mould 2 2 as well as the mould string 4 a distance corresponding to two mould thicknesses. This movement of the mould string 4 is continued in fig. 1 N. Furthermore, operation Opr. 5 Short differs from Opr. 5 Long in that the pressure piston 16 has to travel a shorter distance to get back into the moulding chamber 12.
  • the overlap between the swingable squeeze plate 14, the second mould 2 2 , and the pres- sure piston 16 depends on the speed of the swingable squeeze plate 14, the speed of the second mould 2 2 . i.e. the speed of the mould string 4, the thicknesses of the moulds 2, 2,, 2 ? , and the speed of the pressure piston 16. As the thickness of the moulds increases, longer transport times are needed.
  • Fig. 1N shows a modified Opr. 6, in which the swingable squeeze plate 14 starts to move in to close the moulding chamber 12, and the core setter 40 starts to move in to set the core(s) 42 2 in the second mould 2 2 .
  • the movable mould retainers 22 and the thrust bars 26 of the AMC system still have to advance the mould string 4 the distance of about half of a mould thickness before the stationary mould retainers 24 may engage the second mould 2 2 and the procedure repeats from fig. 1A.
  • the difference from the standard operation Opr. 6 is that the mould string 4 is advanced during the modified operation Opr. 6.
  • the AMC system represented by the thrust bars 26 may be suppleanted by, or combined with a PMC (Precision Mould Conveyor) system, and/or a SBC (Synchronized Belt Con- veyor) system, or any other suitable transport system.
  • PMC Precision Mould Conveyor
  • SBC Synchronized Belt Con- veyor
  • this second mould 2 2 does not have to be brought to the first delivery position A, rather it is only brought to the second delivery position, which is closer to the flaskless moulding ma- chine 10. thereby further decreasing the total travel of the pressure piston 16. This applies to every other second mould produced.
  • Fig. 2 shows a sequence of operations of the flaskless moulding machine 10', the mould conveyor 20', and the pouring unit 30 in a second embodiment of the method according to the first aspect of the present invention.
  • a modified Opr. 3 is performed. This operation differs from the Opr. 3 shown in fig 1C in that the moveable mould retainers 22 already now start to move towards the flaskless mould machine while the thrust bars 26 of the AMC system remain active.
  • the move- able mould retainers 22 and the thrust bars 26 can move in relation to each other.
  • the sta- tionary mould retainers 24 remain active and pouring continues.
  • the first intermediate position is positioned below the swingable squeeze plate 14.
  • Fig. 2F shows the first mould 2 f just prior to being brought into contact with the mould string 4.
  • fig. 2K a modified version of the operation shown in fig 1 K is shown.
  • the thrust bars 26 of the AMC system release and move 2 mould thicknesses closer to the flaskless moulding machine 10 while the movable mould retainers 22 also release and move one mould thickness closer to the flaskless moulding machine 10, i.e. the thrust bars 26 of the AMC system move at a higher speed, indicated with a longer arrow, than the moveable mould retainers 22 so that the movable mould retainers 22 and the thrust bars 26 of the AMC system end up at their end positions at the same time.
  • the rest of the sequence is the same as in the first embodiment.
  • This second embodiment of the method has the advantage that the travel of the pressure piston 16 is further reduced because it only brings the first mould 2i to the first intermediate position, i.e. Opr 4A is short in each of the cycles in the double cycle of the flaskless moulding machine 10 and the mould conveyor 20.
  • operation 4A Short shown in figs. 2K and 2L, may be modified so that the pressure piston 16 delivers the second mould 2 2 to a second intermediate position between the mould string 4, which now includes the first mould 2 1 and the flaskless moulding machine 10 and so that the transport system releases the first mould 2, and moves to this position, whereafter the transport system 22 brings the second mould 2 2 into contact with the first mould 2,.
  • cores 42, 42, and 42 2 are set by the core setter 40 in two different posi- tions along the mould conveyor 20 as shown on figs, 1A and 1 H and 2A and 2H.
  • the core setter 40 is not shown in figs. 2D-F and 2K-M
  • Fig. 3 therefore shows a sequence of operations of the flaskless moulding machine 10", the mould conveyor 20", and the pouring unit 30 in a third embodiment of the method according to the first aspect of the present invention, in which the core setter 40 sets the cores in a single core setting position along the mould conveyor 20.
  • the mould conveyor 20 additionally comprises further stationary mould re- tainers 24, .
  • the moveable mould retainers 22 en- gage the first mould 2, for preventing the pressure piston 16 from drawing it back towards the moulding chamber 12 in the next operation. Pouring continues and the thrust bars 26 of the AMC system remain engaged to the mould string 4.
  • the stationary mould retainers 24 engage the mould 2 while the further stationary mould retainers 24, have no mould to en- gage. In fig. 3F Opr. 5 Short is running.
  • the moveable mould retainers transport the first mould 2, to a core setting position corresponding to the delivery position A. Pouring continues and the thrust bars 26 of the AMC system remain engaged to the mould string 4.
  • the pressure piston 16 is retracting towards the ready position for making the second mould 2 ? .
  • the sta- tionary mould retainers 24 engage the mould 2 while the further stationary mould retainers 24, have no mould to engage.
  • the second mould 2 2 is produced in the flaskless moulding machine 10.
  • the core setter 40 has set the core 42, and is leaving the first mould 2, .
  • the first mould 2 is simultaneously being moved from the core setting position into contact with the mould string 4.
  • Pouring continues and the thrust bars 26 of the AMC system remain engaged to the mould string 4.
  • the stationary mould retainers 24 engage the mould 2 while the further stationary mould retainers 24, have no mould to engage.
  • the stationary mould retainers 24 en- gage the mould 2 while the further stationary mould retainers 24, engage the first mould 2,.
  • the swingable squeeze plate 14 has swung down and is moving in to close the moulding chamber 12.
  • the core setter 40 is moving in to set the cores 42 2 in the second mould 2 2 .
  • the thrust bars 26 of the AMC system engage the mould string 4.
  • the stationary mould retainers 24 engage the mould 2 while the further stationary mould retainers 24, engage the first mould 2,.
  • the core setter 40 is not shown in figs. 3D-G and 3L-0.
  • the method shown in fig. 3 provides for setting cores at one posi- tion only. Further this method is faster than the method shown in fig. 1 due to shorter travel of the pressure piston. By moving the core setting position closer to the mould string, the time for which the core setter 40 blocks movement of the swingable squeeze plate is de- creased.
  • the cores are set while the first and second moulds are moved by the movable mould retainers 22.
  • Fig. 4A shows the time needed for producing and pouring two moulds using a prior art method in which the mould string is advanced one mould for each mould that is produced by the flaskless moulding machine.
  • the time for the two cycles is approxi- mately 13.2 seconds and comprises two pourings of about 5.7 seconds each.
  • the time needed for making one mould is 6.6 seconds, resulting in a production rate of about 545 moulds per hour with realistic movements and speeds.
  • the time needed for producing and pouring two moulds using the first embodi- ment of the method according to the first aspect of the present invention is about 1 1.3 seconds and comprises one pouring where two mould cavities have to be poured simultaneously during 10.1 seconds.
  • the moulding speed can be significantly in- creased while pouring time is also significantly increased. This increase of pouring time comes at the expense of having to pour two moulds simultaneously. Solutions for pouring two moulds simultaneously exist.

Abstract

La présente invention concerne un procédé de multi-indexation de coulées (2, 21, 22) utilisant une machine de coulée en motte (10) pour former des coulées (2, 21, 22) et un convoyeur de coulée (20) pour transporter et faire avancer un aiguillon de coulée (4) produit par une pluralité de coulées (21, 22), reçu par le convoyeur de coulée (20) depuis la machine de coulée en motte (10). Le procédé comprend les étapes consistant à : (i) former une première pluralité de coulées (21, 22), ladite première pluralité comprenant deux élément ou plus, un à la fois utilisant la machine de coulée en motte (10), chacune de la première pluralité de coulées (21, 22) étant ajoutée à l'aiguillon de coulée (4) tandis que l'aiguillon de coulée (4) est fixe ; en étant amené en contact avec l'aiguillon de coulée (4), pour être ensuite produit par la machine de coulée en motte (10). Une fois que la première pluralité de coulées (21, 22) a été produite et ajoutée à l'aiguillon de coulée (4), le procédé passe à l'étape (ii) en éloignant l'aiguillon de coulée (4) de la machine de coulée en motte (10) d'une distance correspondant à la somme de l'épaisseur de la première pluralité de coulées (21, 22) en utilisant le convoyeur de coulée (20) sans assistance de la machine de coulée en motte (10). L'invention concerne également un système de multi-indexation de coulées.
PCT/IB2015/052821 2015-04-17 2015-04-17 Procédé et système pour la multi-indexation de coulées WO2016166578A2 (fr)

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Cited By (1)

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Publication number Priority date Publication date Assignee Title
CN110076293A (zh) * 2019-04-25 2019-08-02 河南广瑞汽车部件股份有限公司 一种控制转向器壳体产生缩松及冲砂的浇注系统及其工艺方法

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Publication number Priority date Publication date Assignee Title
EP0693337A1 (fr) * 1994-07-22 1996-01-24 Georg Fischer Giessereianlagen Ag Dispositif pour le transport d'une ligne de moulage
CN1454128A (zh) * 2000-09-27 2003-11-05 迪萨工业有限公司 模串铸造设备中逐步推进铸模用的方法及设备
US7806161B2 (en) * 2006-12-08 2010-10-05 Thyssenkrupp Waupaca Inc. Molding and casting machine
BR112016002739B1 (pt) * 2013-08-06 2020-11-17 Loramendi, S. Coop método para a produção e o avanço gradativos de peças de molde de areia e sistema para a produção gradativa e o preenchimento de moldes de areia

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110076293A (zh) * 2019-04-25 2019-08-02 河南广瑞汽车部件股份有限公司 一种控制转向器壳体产生缩松及冲砂的浇注系统及其工艺方法
CN110076293B (zh) * 2019-04-25 2024-02-27 河南广瑞汽车部件股份有限公司 一种控制转向器壳体产生缩松及冲砂的浇注系统及其工艺方法

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