The present invention relates to electric induction melting assemblies, and in particular, to such assemblies operating in a vacuum or other controlled environment, and rapid connect or disconnect of electric power to a removable induction melting furnace used in such assemblies.
An electric induction melting assembly can be used in a vacuum to produce high purity alloy metals. The electric induction melting assembly can comprise an induction melting furnace (sometimes referred to as a refractory crucible) that is seated in a tilting cradle located within an industrial vacuum chamber. The furnace can be tilted in the cradle about a trunnion that is rotatably supported on a bearing so that molten metal product can be poured from the furnace into a mold or other containment vessel.
The induction melting furnace requires removal from the vacuum chamber for replacement or repair of the furnace, or to exchange one furnace with another. Removal of the induction melting furnace in some conventional vacuum induction melting assemblies can be time consuming since a hot operating furnace must remain in the chamber with cooling water flowing through the induction coil for an extended period of time to cool the furnace before electric power and cooling water source connections are manually disconnected from the furnace. This conventional procedure for repair or exchange of the furnace results in a significant loss of productivity caused by the required cooling time along with the period of time normally required for manually disconnecting and reconnecting a furnace. U.S. Pat. No. 5,125,004 (to Roberts et al.) is an example of a method of achieving a rapid exchange of power and cooling connections.
One object of the present invention is to achieve the connection of electric power to a vacuum induction melting furnace within a pressurized interior space of the furnace assembly's tilting cradle, or other mating assembly component within the vacuum chamber so that the connection or disconnection of electric power can be achieved without substantial cool down of a hot in-service induction melting assembly.
In one aspect, the invention is apparatus for, and method of connecting or disconnecting electric power to a vacuum induction melting furnace being installed or removed from a vacuum environment where the electrical connection is made within a pressurized interior environment of a component of the furnace assembly installed in the vacuum or otherwise controlled environment.
In another aspect the present invention is an electric induction melting assembly for use in a controlled environment chamber, such as a vacuum chamber. The electric induction melting assembly comprises an induction melting furnace and a cradle for seating of the induction melting furnace within the controlled environment chamber. The induction melting furnace has furnace induction coil power leads from one or more induction coils surrounding a crucible of the induction melting furnace. The induction melting furnace also has a furnace spade assembly that includes a pressure plate with an opening to a controlled environment in the controlled environment chamber. A furnace spade power port seals the opening in the pressure plate. Positive and negative furnace electrical spades protrude through the furnace spade power port. The furnace induction coil power leads are connected to the positive and negative furnace electrical spades on the controlled environment side of the pressure plate. The cradle, which can be a tilting cradle, has at least one external electric power port for connecting an external source of electric power to the furnace's induction coil(s). The cradle also has a cradle spade assembly disposed within an interior cradle volume that has a furnace electrical spades opening. A cradle spade assembly includes positive and negative cradle electrical spades that are connected to the external source of electric power via the external electric power port. The cradle also has a clamping assembly within the interior cradle volume that has alternative opened and closed positions. A spade clamping assembly includes positive and negative cradle clamping electrical spades and an actuator for moving the positive and negative cradle clamping electrical spades between the opened and closed positions. The positive and negative cradle clamping electrical spades are disposed on opposing sides of the positive and negative cradle electrical spades so that when the pressure plate is sealed against the furnace electrical spades opening and the positive and negative furnace electrical spades protrude into the interior cradle volume a sealed cradle environment is formed within the interior cradle volume in which volume the dry-break opening and closing of the cradle electrical spades can be accomplished. The sealed cradle environment is isolated from the controlled environment established within the controlled environment chamber whereby when the cradle spade clamping assembly is in the closed position the positive cradle clamping electrical spade and the negative cradle clamping electrical spade respectively close an electrical circuit between (1) the positive furnace electrical spade and the positive cradle electrical spade and (2) the negative furnace electrical spade and the negative cradle electrical spade in the sealed cradle environment. The electric induction melting assembly may have one or more interior cradle volumes with componentry as described above.
In another aspect the present invention is a method of operation of an induction melting furnace removably installed in a cradle disposed in a controlled environment within a controlled environment chamber. The induction melting furnace has furnace coil power leads from one or more furnace induction coils supplied to positive and negative furnace electrical spades disposed in a furnace spade power port sealably attached to a pressure plate on the induction melting furnace with the positive and negative furnace electrical spades penetrating through the pressure plate. The induction melting furnace is seated on the cradle prior to establishing the controlled environment within the controlled environment chamber so that the pressure plate forms a seal over a furnace electrical spades opening in an interior cradle volume with the positive and negative furnace electrical spades penetrating into a sealed interior cradle environment in the interior cradle volume. The interior cradle volume contains a cradle spade assembly and a spade clamping assembly. The controlled environment is established within the controlled environment chamber subsequent to seating the induction melting furnace on the cradle to isolate the sealed interior cradle environment from the controlled environment. Positive and negative cradle clamping electrical spades associated with the spade clamping assembly are moved from an opened to a closed position within the sealed interior cradle environment to close an electrical circuit between the positive furnace electrical spade that protrudes through the pressure plate into the sealed interior cradle environment and the positive cradle electrical spade associated with the cradle spade assembly. The positive cradle electrical spade is connected to the positive terminal of an external power source. Moving the positive and negative cradle clamping electrical spades from the opened to the closed position also closes an electrical circuit between the negative furnace electrical spade that protrudes through the pressure plate into the sealed interior cradle environment and the negative cradle electrical spade associated with the cradle spade assembly. The negative cradle electrical spade is connected to the negative terminal of the external power source whereby electric power from the positive and negative terminals of the external power source is provided to the one or more induction coils of the induction melting furnace. For removal of the induction melting furnace from the controlled environment chamber, the positive and negative cradle clamping electrical spades are moved to the opened position within the sealed interior cradle environment and the electrically disconnected induction melting furnace can be removed from the controlled environment chamber.
The above and other aspects of the invention are set forth in the specification and the appended claims.
The figures, in conjunction with the specification and claims, illustrate one or more non-limiting modes of practicing the invention. The invention is not limited to the illustrated layout and content of the drawings.
There is shown in
Components associated with the furnace 10 can include separate water-only connections 46, furnace induction coil(s) power leads 34, and furnace spade assemblies 35 as further described below. The illustrated separate water-only connections 46 and separate power leads 34 are used in an arrangement and method of connecting a water supply and coil power leads to the furnace for a dry-break electrical disconnect where the water and electric power are not supplied with common componentry.
Components associated with the tilting cradle 12 can include one or more cradle electric power ports 36 and spade clamping and cradle spade assemblies 37 (located interior to the cradle) as further described below. During a furnace removal process, each spade clamping assembly is unclamped (opened position) and the water-only connections are disconnected. The furnace is then unfastened from the tilting cradle and removed vertically (illustrated by arrow in
Furnace spade assembly 35 comprises the following componentry in this example of the invention. Pressure plate 42 is suitably attached to furnace 10 (via offset posts 42a in this example). Positive and negative furnace electrical spades 16 and 24 are disposed within the pressure plate and protrude below the pressure plate as best seen in
A vacuum tight seal can be maintained by pressure plate 42 over an opening into internal volume 29 of cradle enclosure 27 to seal the cradle's interior volume that houses the spade clamping and cradle spade assemblies 37. The seal can be established, for example, by precision finishing of the facing surfaces of pressure plate 42 and the top 27a of cradle enclosure 27 with furnace 10 seated on the cradle to establish a close tolerance surfacing between the facing surfaces as required for a particular application. That is, the close tolerance surfacing achieves the required degree of sealing between the facing surfaces for a particular application. Alternatively the pressure plate can be spring-loaded fastened over the opening into internal volume 29 by a suitable spring-load clamping apparatus that is attached either to the furnace or cradle and clamps the pressure plate to the top of the cradle enclosure after the furnace is seated on the cradle. With either method one or more suitable sealing elements, such as gasket 15 may also be used to achieve the required level of sealing for a particular application. Further securing the furnace to the cradle, for example by fasteners, after seating of the furnace in the cradle may also be used to achieve the required level of sealing for a particular application.
Sealed interior volume 29 of cradle 12 is maintained at a nominal pressure that is greater than vacuum, or otherwise different from the controlled environment in which the induction furnace will be utilized in. Typically this interior volume will be an air composition at, or near, atmospheric pressure. The interior volume is pressurized since furnace 10 is installed (seated) on the cradle when the vacuum chamber (and the cradle's interior volume 29) is open to ambient air pressure prior to seating of pressure plate 42 over the opening into the cradle's internal volume 29; once the pressure plate is seated over the opening and sealed as described above, the vacuum chamber can be sealed and a vacuum can be established in the chamber for normal operation of the induction melting assembly while a pressurized environment is maintained with the cradle's interior volume. Alternatively if cradle power ports 36 are located external to the vacuum chamber as further described below, the sealed interior of the cradle may be open to atmosphere adjacent to the power ports that are external to the chamber's wall.
Located inside each interior volume of the tilting cradle is at least one spade clamping and cradle spade assemblies 37. A cradle spade assembly comprises the following componentry in this example of the invention. Positive and negative cradle electrical spades 22 and 26 are suitably separated from each other, for example, by cradle spade insulator plate 23 formed from an electrical insulating material.
The positive and negative cradle electrical spades 22 and 26 can be electrically connected within titling cradle 12 to an external power source via cradle power port 36 as further described below. Supply electric power can be provided to the cradle power ports 36 from one or more electric power sources. Cradle power port 36 can be located either internal or external (as further described below) to the vacuum chamber.
Each spade clamping assembly comprises the following componentry in this example of the invention: clamping guide supports 18; guided spade clamping frames 19, spade clamp electrical insulator plates 20, and positive and negative electrical spade clamps 21 and 25. Supports 18 function as structural clamping guides. Guided spade clamping frames are connected to a suitable actuator (not shown in the figures) to clamp the electrical spade clamps against their respective furnace and cradle electrical spades to supply the furnace coil(s) with electric power during furnace operation (power connect or closed position) and to unclamp the electrical spade clamps during furnace removal (power disconnect or opened position). The electrical spade clamps 21 and 25 are shown in the (unclamped) power disconnect position in
The clamping guide supports, guided spade clamping frames, spade clamp electrical insulator plates, and electrical spade clamps 21 and 25 represent one means of selectively clamping the furnace and cradle electrical spades together within interior volume 29 of the cradle, and other means performing the same function within the interior volume are contemplated within the scope of the invention as long as they include a clamping electrical conductor for clamping against adjacent furnace and cradle electrical spades to close a circuit between the spaced apart furnace and cradle electrical spades when the interior volume of the cradle is sealed as described above.
Electrical spade clamps 21 and 25 may serve as the electrical conducting elements between the spaced apart furnace and cradle electrical spades, or may be configured with electrically conductive inserts that complete the electrical connections between the spaced apart lower ends of the furnace electrical spades 16 and 24, and the upper ends of the cradle electrical spades 22 and 26 as shown in
While the spade clamping and cradle spade assemblies 37 are located in a tilting cradle in the above examples of the invention, these assemblies may be installed in other components associated with the induction melting system within the vacuum or otherwise controlled environmental chamber in other examples of the invention. For example, if the furnace is a non-tilting furnace, the furnace may be seated in a fixed cradle within the chamber, and the spade clamping and cradle spade assemblies 37 may be installed within this fixed cradle.
While the above examples of the invention illustrate an electric induction melting assembly wherein a single phase alternating current source (with negative and positive instantaneous voltage and current designations) is supplied to the induction furnace, a multi-phase alternating current source is within the scope of the invention with additional componentry as described herein for additional phases of the multi-phase supply.
The term “electrical spade” is used herein to generally mean an electrically conductive plate material.
The present application is of particular use in vacuum induction melting quick change, low volume furnace applications.
The examples of the invention include reference to specific components. One skilled in the art may practice the invention by substituting components that are not necessarily of the same type but will create the desired conditions or accomplish the desired results of the invention. For example, single components may be substituted for multiple components or vice versa.
This application claims the benefit of U.S. Provisional Application No. 61/523,609 filed Aug. 15, 2011, hereby incorporated herein by reference in its entirety.
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