Module casting systems with shared controls

Information

  • Patent Grant
  • 6648058
  • Patent Number
    6,648,058
  • Date Filed
    Tuesday, June 11, 2002
    22 years ago
  • Date Issued
    Tuesday, November 18, 2003
    21 years ago
Abstract
A modular casting system includes a plurality of casting modules and, is provided with on-board systems such as a lubrication system, cooling system, etc., which operate independently from similar systems on other modules of the system. Each of the casting modules is connected by quick disconnect connections to a centrally disposed source of fluid pressure and electrical power and a control unit for controlling each of the modules independently. Each of the modules is readily removable from the system and replaced with a new module of a different type or with a different mold. Each of the modules is preferably provided with a filter removal unit which is operative to raise the filter during the cooling operation and facilitates removal of the filter upon completion of the pouring operation. The upper platen of a casting module is provided with a swinging cope which is movable between a horizontal position and a vertical position to facilitate cleaning of the cope. The lower platen is preferably provided with a pneumatic hydraulic cylinder arrangement including a mechanism for raising the casting from the drag.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




The invention relates to automated casting systems and more particularly to a casting system employing a plurality of casting units disposed on a rotating table or the like.




2. Background Art




A casting system, besides a casting mold, typically includes a mechanism for opening and closing the mold and a variety of electrical, pneumatic, and/or hydraulic systems which serve to perform a variety of controlling functions in the overall molding process. Furthermore, lubrication systems and cooling systems may be required. A problem with prior art casting systems is the difficulty encountered in substituting a different configuration mold in an existing system. Since molds of various different shapes and configurations may be required from time-to-time and connections for the various systems to control the molding apparatus may vary substantially between molds, the changeover from one set of molds to another results in significant and expensive downtime for the casting system. Such changeover may require re-routing of electrical cabling and connections for pneumatic and hydraulic as well as cooling systems. Furthermore, in typical prior art arrangements, a plurality of molds and the apparatus for opening and closing the molds are disposed on a rotating table or the like. In case of a breakdown or routine maintenance of the opening and closing mechanism for a particular mold or of the mold itself, the entire casting system must be shut down. Such a shut-down tends to be time-consuming since the system typically has to be cooled down for maintenance work and must be brought back to working temperature before operations can be resumed. A particular disadvantage of prior art systems is the costly downtime of the entire system for maintenance, repair or changeover of molds.




Routine molding operations typically require that a filter used in the casting operation be removed and replaced before a next pouring of the molten metal or the like. This is commonly done manually. In order to avoid introducing the necessary delays in the casting operation, the filter is typically removed as soon as possible after the previous pouring operation, often while it is still very hot. The filter removal can be both difficult and time-consuming. A further difficulty in the routine operation of a casting system is that the mold is preferably laundered after a casting operation and coated with a specialized coating prior to the next pouring. The functions of laundering and coating are typically performed manually and tend to be difficult and time consuming, adding to the cost of the casting operation.




A further difficulty in many casting operations is the removal of a casting from the mold, particularly from the drag of the mold, while the casting is hot.




SUMMARY OF THE INVENTION




These and other problems of the prior art are overcome in accordance with this invention in a modularized system comprising a plurality of casting modules, each of which may be removed from a casting system, such as a rotating table casting system, without affecting the operation of other modules. Each module is provided with on-board systems such as a lubrication system, a cooling system, etc., which operate independently from similar systems on other modules. Each module is provided with quick-disconnect connectors for connection to a main source of electrical power, hydraulic pressure, etc. The modules are preferably interchangeable and a variety of different modules may be installed in one main system and can be readily exchanged as required by production demands, without significant system downtime.




A particular advantage of the modular system is that a casting module may be removed and replaced in a relatively short period of time since only a few connections need to be made. Furthermore, periodic maintenance and repair of the modules may be performed off-line with a minimum of production line down-time.




Advantageously, in accordance with another aspect of the invention, a casting module of the system may be replaced by another module which has not only been set up and tested off-line, but also warmed up off-line to bring the unit up to the desired operating temperature. In a system in accordance with this invention, the replacement of a casting module requires the casting operation be interrupted only for a period of time sufficient to disconnect a number of quick-disconnect connections, remove the casting module by means of a forklift or the like, replace the removed module with a preheated casting module and make the necessary quick-disconnect connections. Advantageously, since the new unit has been warmed up off-line and since the other units are not taken out of operation for an extended period of time, no significant system warm-up time is required and system downtime is reduced substantially.




In accordance with another aspect of the invention, a casting unit is provided with a mechanism for mechanically removing a filter that is used in the casting process. In accordance with one specific aspect of the invention, the casting unit includes a pneumatic or hydraulic cylinder mounted on a pivoting bracket having spaced apart arms attachable by means of chain or the like to a filter to be removed. Advantageously, the filter may be raised during the pouring operation such that it is completely removed from the casting before the casting solidifies, thereby avoiding certain problems of the prior art associated with the removal of filters from a casting.




In accordance with another aspect of the invention, a cope of a casting system provided with a tilting launder tray, preferably mounted on the upper platen, that is readily moved aside during the pouring operation and quickly put in the appropriate position to direct a laundering liquid into a filler neck of the upper platen.




In accordance with another aspect of the invention, the upper platen of a casting system is provided with a swinging cope which is movable between the horizontal position, in which the cope is disposed adjacent a lower surface of the upper platen, and a vertical position in which the cope is extended at a 90 degree angle to the upper platen.




Advantageously, the movable platen greatly facilitates cleaning of the cope prior to a next pouring operation. In one specific embodiment of the invention, the cope is movable between the horizontal and vertical positions by one or more hydraulic or pneumatic cylinders and a hydraulic or pneumatically operated locking mechanism is provided to lock the cope in place adjacent to the upper platen.




In accordance with yet another aspect of the invention, the lower platen is advantageously provided with a pneumatic or hydraulic cylinder arrangement which serves to raise the lower platen for easier removal of a casting and is further provided with a mechanism for lifting a casting from the drag.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a plan view of a casting table supporting a plurality of casting modules;





FIG. 2

is a front elevational view of a casting module in accordance with the invention;





FIGS. 3A and 3B

are left and right elevational views, respectively, of the module

FIG. 2

;





FIGS. 4A and 4B

depict enlarged breakaway views of a filter lift mechanism in accordance with the invention;





FIG. 5

is a plan view of a bracket for mounting a filter lift cylinder in the mechanism of

FIGS. 4A and 4B

;





FIG. 6

is a side elevational view of a casting unit which is an alternate embodiment of the casting unit of

FIGS. 2-5

;





FIG. 7

is a plan view along line


7





7


of

FIG. 6

showing a launder tray and a cope operating mechanism;





FIG. 8

is a partial breakaway side elevational view of the casting unit at

FIG. 6

showing the launder tray in an operating position;





FIG. 9

is a partial breakaway side elevational view of the casting unit of

FIG. 6

showing the swinging cope


203


in the closed position;





FIGS. 10 and 11

are partial cutaway right elevational views of

FIG. 6

showing the cope locking mechanism in locked and unlocked states, respectively; and





FIG. 12

is a partial cutaway enlarged frontal elevational view of the dual action lower cylinder of FIG.


6


.











DETAILED DESCRIPTION





FIG. 1

is a plan view schematic representation of a rotatable casting table


10


provided with a plurality of casting modules


100


and a central hub area


20


incorporating control and supply systems. The control and supply systems are connected to each of the modules


100


by means of control and supply lines


25


. Each of the casting modules


100


is preferably connected to an associated control supply line


25


by means of a quick-disconnect connector


30


. The central hub area


20


preferably includes an electronic controller


35


, a hydraulic unit


40


providing hydraulic fluid under pressure, an air supply unit


45


providing air under pressure and an electrical supply box


50


. The controller


35


may, for example, be a programmed logic array designed to provide electrical signals to various ones of the casting modules


100


to operate various air and/or hydraulic valves and/or relays. The programmed logic array may also receive signals from the various units


100


indicative of certain operations, such as actuation of limit switches, etc. The electrical supply box


50


provides electrical power to the various units


100


, when required. A filling station


60


provides a source of molten material to be used in the casting modules


100


. The casting table


10


may be rotated to place a casting module


100


adjacent the filling station


60


. Molten material may be transferred from the filling station


60


to a casting module disposed adjacent the filling station through a transfer conduit


65


or ladle or the like.





FIG. 2

is a frontal view of a dual casting module


100


consisting of two independently operable casting units


102


,


104


. Each casting unit is provided with an upper platen


106


for supporting a cope of a mold (not shown in the drawing) and a lower platen


108


for supporting a drag of a mold (not shown in the drawing). For the sake of clarity, one of the casting units is shown in the open position in which the upper platen is spaced apart from the lower platen and the other of the casting units is shown in a closed position in which the upper platen is disposed adjacent the lower platen. The two casting units


102


,


104


operate in the same manner but are independently controlled by the controller


35


. By constructing dual unit casting modules, rather than single unit casting module, a substantial savings in construction material and system connections will be realized while obtaining modularity of the system. It will be apparent that single unit casting modules may be constructed as well. In one particular application, the dual casting modules are used to cast different parts of a unit to be assembled. A casting unit, such as the dual casting unit


102


,


104


consisting of two sets casting modules, may be readily moved by means of a forklift or other lifting equipment onto the rotating table


10


, such that the advantages of modularity are not lost by the use of a dual unit. It will be understood that the invention applies to single units in the same manner as it applies to dual units described herein.




The upper platen


106


, is moveable between a lowered position in which the cope of the mold (not shown in the drawing) supported on the upper platen


106


is disposed in immediately adjacent the drag of the mold (not shown in the drawing) supported on the lower platen


108


, and a raised position in which the cope is spaced apart from the drag. When the cope is in the lowered position, the cope and the drag together form a mold ready to receive molten metal from a ladle or the like. The raising and lowering of the upper platen


106


is achieved by means of a hydraulic lift cylinder


112


having a movable shaft


113


connected to cross beam


115


. The cross beam


115


is mounted to a pair of lift rods


117


extending from the cross beams


115


through guides


110


to the upper platen


106


. Upper guide bearings


119


and lower guide bearings


120


are provided on upper and lower ends, respectively, of the guides


110


. The guide bearings are preferably provided with a wiper seal or the like engaging the surface of the guide rods and a lubricating oil may be provided to the bearings for purpose of cooling and lubrication. The lift cylinders


112


are actuated via a control valve


121


which selectively applies hydraulic fluid under pressure from hydraulic unit


40


to the upper and lower ends of lift cylinders


112


via hydraulic quick disconnect


122


and control valve


121


, thereby controlling the movement of the upper platen


106


. The control valve


121


is actuated in response to signals from controller


35


applied via electrical quick disconnect


126


and electrical conductors


124


. Further shown in

FIG. 2

, associated with the raising and lowering mechanism of the upper platen


106


, is an upper platen trip rod


116


. The trip rod


116


is designed to activate a switch


111


when the upper platen is lowered to its desired position. The two switches


111


are connected to the electrical disconnect plug


126


to transmit appropriate signals to the controller


35


when the switches are actuated. For the sake of clarity, the various electrical and hydraulic connections are not shown in the drawings.




The lower platen


108


is supported on a lower platen lift cylinder


114


and lift cylinder shaft


130


. The lift cylinder


114


is operated to raise the lower platen to facilitate removal of a casting after the casting operation has been completed and the upper platen has been raised. The lift cylinder


114


is connected by means of hydraulic lines (not shown in the drawing) to the control valve


121


which, as mentioned earlier, is operated by electrical control signals from the controller


35


via the quick disconnect


126


and appropriate ones of the conductors


124


. The lower platen


108


is supported on guide rods


135


extending through bearings


136


. Connected to one of the guide rods


135


is a trip rod


138


which serves to actuate limit switches


139


,


140


to indicate the position of the lower platen. The limit switches are electrically connected by selected ones of the conductors


124


to quick disconnect


126


to provide an indication to the controller


35


of the position of the lower platen.




Further shown in

FIG. 2

is a pair of oil pumps


142


and an oil supply reservoir


145


. The pumps and the reservoir, together with oil supply and return lines (not shown in the drawings) interconnecting the reservoir


145


, the pumps


142


and the bearings


119


,


120


and


136


are part of a closed bearing lubrication and cooling system in which oil is drawn from the reservoir


145


and supplied to the bearings by the pumps


142


under pressure and is returned to the reservoir. When the lower platen


108


is lowered to the normal position for casting, a lube cam


123


actuates the oil pump


142


which distributes the oil under pressure to the bearings


119


,


120


and


136


via oil supply lines and a series of standard distribution blocks (not shown in the drawings). The oil is returned from the bearings to the reservoir via the oil return lines to be reused.




Referring now to

FIGS. 2 through 5

, there is shown in

FIG. 2

a filter element


150


in each of the casting units


102


,


104


. When a mold disposed between the upper and lower platens is in the closed position, a molten substance, such as a molten metal, is poured into the mold from a ladle or the like through an opening in the upper platen


106


. A filter element


150


is provided in alignment with such opening for filtering the molten metal. Such filter elements and the use thereof in the casting process are well known in the art. In the partially cut-away right side elevational view of

FIG. 3B

there is shown a filter removal unit


152


, for lifting the filter element


150


during a pouring. The filter element


150


is initially disposed adjacent the upper platen and is gradually lifted by the filter removal unit


152


during the pouring operation. Lifting the filters during the pouring operation facilitates removal of the filters before the casting begins to solidify avoids a significant problem encountered in prior art systems wherein the filter is removed after the pouring operations have been completed.




As shown in detail in

FIGS. 4A

,


4


B and


5


, the filter removal unit


152


comprises a hydraulic lift cylinder


157


, mounted on cylinder support bracket


151


, and a piston rod


158


having a free end mounted to the frame


148


. The support bracket


151


comprises a pair of spaced apart lift arms


153


A,


153


B each pivotally mounted to an upstanding support bracket


163


mounted on the frame


148


. A chain


155


is connected from each of the lift arms to opposite sides of the filter element


150


. The cylinder


157


has fluid connections to control valve


121


and is operated in response to operation of the control valve


121


by controller


35


.

FIG. 4A

shows the filter removal unit


152


in the fully raised position and

FIG. 4B

shows the filter removal unit


152


in the fully lowered position. The cylinder


157


has a piston rod


158


having an end engaging a flattened surface


161


of a spherical rod eye


159


, which is pivotally mounted on pivot


160


by a bracket


166


supported in a clevis bracket


162


mounted to the frame


148


. Cylinder


157


is mounted to a cylinder pivot pin


164


by means of brackets


165


. The cylinder pivot pin


164


is rotationally mounted to end brackets


166


, along the pivot centerline


154


, to allow the cylinder support bracket


151


to pivot relative to the lift cylinder


157


between the positions shown in

FIGS. 4A and 4B

. As the cylinder


157


is actuated, the support bracket


161


is pivoted on pivot point


156


and the lift arms


153


A, B are moved between the raised and lowered positions as shown in

FIGS. 4A and 4B

, respectively.




Referring now to

FIGS. 6 through 12

, there is shown an alternate embodiment of casting units


102


,


104


. The casting unit


201


is provided with a swinging cope


203


which is rotatably attached to the upper platen


205


. The upper platen is supported on lift rods


217


extending through guides


210


and is shown in

FIG. 6

in the raised position. The swinging cope


203


is supported on a pivot


207


on the upper platen


205


. A pair of spaced apart hydraulic or pneumatic cylinders


209


is operable to move the cope from the open position shown in

FIG. 6

to a closed position, as shown in

FIGS. 8 and 9

, in which the upper surface


204


of the cope


203


is disposed immediately adjacent the lower surface


206


of the upper platen


205


. The lower surface of the cope is typically coated before each casting operation. In a production facility, such a coating may have to take place every three minutes. The swinging cope allows for quick and easy access for such coating purposes.




The cylinders


209


are each provided with a piston rod


240


having one end engaging the swinging cope at brackets


242


. Each of the cylinders


209


has a fixed end


244


mounted to the top surface of the upper platen


205


by means of a mounting bracket


246


. As readily apparent from the drawing, the cope


203


is disposed immediately adjacent the upper platen when the piston rod


240


is extended and is in the full down position when the piston rod


240


is retracted. The cope


203


is retained in a locked position with respect to the upper platen


205


by means of a locking mechanism


248


.

FIG. 10

shows the locking mechanism in the locked position and

FIG. 11

shows it in the released position. As shown in the drawing, the cope


203


is provided with a pair of pins


250


and a pneumatic or hydraulic cylinder


252


is used to actuate a pair of latches


254


, mounted on the upper platen


205


. The latches are pivotally mounted on the platen


205


by means of pivot pins


256


. The cylinder


252


is mounted to the two latches


254


by means of pivot pins


258


. When the cylinder


252


is in the extended position, as shown in

FIG. 11

, the latches


254


are in the released position and the upper platen


203


may be lowered to the open position as shown in FIG.


6


. After the lower platen


203


has been rotated to the position shown in

FIGS. 10 and 11

, the cylinder


252


is operated to the retracted position which causes the latches


254


to be rotated about the pivot pins


258


thereby engaging the pivot pins


250


and drawing the cope


203


against the upper platen


206


.




Further shown in

FIGS. 6 through 9

is a launder tray


220


. The launder tray


220


is pivotally mounted on axis


221


supported on a pair of spaced apart brackets


222


mounted to the upper platen


205


by fasteners


228


. The launder tray has a filler neck


225


engaging a filler opening


227


in the upper platen


205


. Further shown in

FIGS. 6 and 12

is a dual action lower cylinder arrangement


230


comprises an upper cylinder


231


for raising and lowering the lower platen and a lower cylinder


232


. The lower cylinder


232


engages a lower bracket


234


provided with vertically extending rods


235


and


236


engaging an upper bracket


238


. The bracket


238


is provided with vertically extending pins


236


extending into a lower portion of the lower platen


208


and engaging a plate


239


supporting pins


240


. When the hydraulic cylinder


232


is actuated, the brackets


234


and


238


are raised and pins


240


, extending through openings in the lower platen, serve to raise the casting in the mold to facilitate removal of a casting from the mold.




Shown in

FIG. 12

is an enlarged breakaway view of the lower platen lift mechanism with a casting removal assist mechanism shown is FIG.


6


. An upper hydraulic or pneumatic cylinder


232


is mounted to cross-member


260


and, when operated, actuates the piston


262


to raise or lower the upper platen


205


, to facilitate removal of a casting from a mold


270


. A lower hydraulic or pneumatic cylinder


231


is mounted to the cylinder


232


by means of flanges


233


. When the lower cylinder


231


is actuated, a piston


264


raises a lower bracket


234


in the direction of the lower platen


208


. A pair of vertically extending rods


235


are mounted on the lower bracket


234


and engage an upper bracket


238


. Mounted on the upper bracket


238


are vertically extending rods


236


which extend through the lower platen


208


and engage a horizontally extending plate


239


. Vertically extending rods


240


are mounted on plate


239


and extend through the lower portion of the mold or drag. When lower cylinder


231


is actuated, rods


240


engage and raise a casting disposed on the drag to a position where it is lifted from engagement with the drag. Advantageously, this arrangement facilitates the removal of a casting from the drag.




Further shown in

FIG. 6

is a dual action lower cylinder


230


having an upper portion


231


for raising and lowering the lower platen and a lower portion


232


. The lower portion


232


engages a horizontally extending bar


234


provided with vertical members


235


and


236


engaging a upper horizontal bar


238


. The bar


238


is provided with vertically extending pins


239


extending into a lower portion of the lower platen


208


. When the hydraulic cylinder


232


is actuated, the horizontal bars


234


and


238


are raised and the pins


240


extending through openings in the lower platen serve to eject the casting from the mold.




It is to be understood that the above-described arrangement is merely illustrative of the application of the principles of the invention and that other arrangements may be devised by those skilled in the art without departing from the spirit and scope of the invention as defined by the appendant claim:



Claims
  • 1. In a casting apparatus, a removal unit for use in a casting module having an upstanding frame and an upper platen disposed within the frame and an opening in the upper platen for receiving a molten substance and a filter having opposing sides and disposed above the upper platen for filtering the molten substance, the filter removal unit comprising:a lift cylinder; a filter lift frame; and a connection linkage extending from the filter lift frame to the filter; the filter lift frame having first and second opposing side members, each of the opposing side members having one end mounted to the upstanding frame and a free end; a first connecting linkage extending from the first side member and connected to one of the first and second opposing sides of the filter; a second connecting linkage extending from the second side member and connected to another of the opposing sides of the filter; the lift cylinder comprising a lift cylinder housing and a piston rod extending from the lift cylinder housing, one of the lift cylinder housing and the piston rod pivotally engaging each of the first and second opposing side members and another of the lift cylinder housing and the piston rod pivotally mounted to the upstanding frame.
Parent Case Info

The application is a divisional of application Ser. No. 09/851,808, filed May 9, 2001, abandoned, which is a divisional of application Ser. No. 09/362,150, filed Jul. 28, 1999, now U.S. Pat. No. 6,425,435, issued Jul. 30, 2002.

US Referenced Citations (4)
Number Name Date Kind
4105560 Fismer Aug 1978 A
4880374 Hamamura et al. Nov 1989 A
5879721 Bradley Mar 1999 A
6425435 Macheske et al. Jul 2002 B1
Foreign Referenced Citations (4)
Number Date Country
62-197263 Aug 1987 JP
64-66066 Mar 1989 JP
1-181962 Jul 1989 JP
6-31382 Feb 1994 JP