TECHNICAL FIELD
This disclosure relates to devices and methods for applying vibrational energy to manufacturing equipment transferring molten metal.
BACKGROUND
Conventional molten metal steel mill applications include a ladle used to temporarily store molten metal, for example molten steel, that is transferred to downstream equipment and processes wherein the molten metal solidifies and is used to manufacture metal components. Particulates are used in the ladle to prevent premature solidification of the molten metal in the ladle well prior to the transfer of the molten metal from the ladle. By design, on the opening of the slide gate allowing the molten metal to exit the ladle, the particulates quickly dislodge from the ladle well and pass along with the exiting molten metal allowing for a free flow of molten metal from the ladle.
Often, the particulates do not dislodge and flow out of the ladle well with the molten metal and completely or partially obstruct the flow of molten metal exiting the ladle. The failure of the particulate to dislodge results in a blockage or reduced flow of the molten metal from the ladle which can affect the transfer, properties and quality of the molten metal in the ladle and in subsequent process steps.
Conventional solutions require injecting high pressure gas, for example oxygen, and/or a pressurized flame or torch into the area of the particulate obstruction to break up or unclog the obstruction to initiate the free flow of molten metal from the ladle. Alternately, the pressurized flame may be used to clear a partial obstruction of particulate to restore free flow of the molten metal from the ladle. Due to the high temperatures and harsh environment around the ladle and molten metal, the conventional solutions are difficult to execute and expose operators to the high temperatures and harsh environment. Further, injecting gas into the area of the molten metal to clear the particulate obstruction can have an adverse effect on the intended properties and quality of the molten metal.
Improvements are needed to conventional solutions to achieve devices and methods useful to initiate or restore a free flow of molten metal in the molten metal transfer equipment and processes, maintain the properties and quality of the molten metal, and achieve increased safety for operators.
SUMMARY
Disclosed herein are vibratory systems and methods for use in transferring molten metal.
In one example, a vibratory system for use in transferring molten metal is disclosed. In the system, a ladle is configured to store molten metal. The ladle defines a cavity to store the molten metal and a ladle opening is configured to allow the molten metal to exit the ladle. The ladle opening is in communication with the cavity. A slide gate is connected to the ladle in communication with the ladle opening. The slide gate is configured to selectively allow the molten metal to flow from the cavity through the ladle opening. A vibrator is in vibratory communication with the ladle and is configured to generate vibrational energy. The vibrational energy is operable to dislodge a particulate positioned in the ladle opening allowing the molten metal to exit through the ladle opening unobstructed by the particulate.
In one example, a transfer device is used which defines a passage for the molten metal. The transfer device is configured to selectively engage the slide gate allowing the molten metal to pass through the slide gate and then through the passage of the transfer device. In one example, the transfer device includes a first position wherein the transfer device is disengaged from the slide gate and a second position wherein the transfer device is engaged with the slide gate. The transfer device is configured to reciprocally move between the first position and the second position allowing the molten metal to flow through the passage of the transfer device unobstructed by the particulate. In one example, the vibrator is connected to the transfer device.
In one example, the slide gate includes a first position wherein the slide gate prevents the flow of molten metal through the slide gate, and a second position wherein the slide gate allows the flow of molten metal through the slide gate. In the example, the vibrator is connected to the slide gate and is configured to transfer the vibrational energy to the ladle to dislodge the particulate when the slide gate is in the second position allowing the flow of the molten metal to exit the ladle unobstructed by the particulate.
In one example, the vibrator is connected to the ladle and is configured to transfer the vibrational energy to the ladle to dislodge the particulate allowing the flow of the molten metal to exit the ladle unobstructed by the particulate.
In one example, the vibrator is a high frequency vibrator configured to generate high frequency vibrational energy.
In another example of the vibratory system, the ladle is configured to store molten metal. The ladle defining a cavity to store the molten metal and a ladle opening configured to allow the molten metal to exit the ladle. The ladle opening is in communication with the cavity. A slide gate is connected to the ladle and configured to selectively allow the molten metal to flow from the cavity through the ladle opening. In one example, the slide gate includes a first position configured to prevent the flow of molten metal through the slide gate, and a second position configured to allow the flow of molten metal through the slide gate.
A transfer device includes a first position wherein the transfer device is disengaged from the slide gate and a second position wherein the transfer device is engaged with the slide gate. In one example, the transfer device includes an articulatable arm and a shroud. The shroud is connected to the articulatable arm and is configured to engage the slide gate when the transfer device is engaged with the slide gate. A vibrator is in vibratory communication with the ladle. In one example, the vibrator is connected to the articulatable arm and is configured to generate and transfer high frequency vibrational energy to the ladle to dislodge a particulate, for example sand, positioned in the cavity of the ladle obstructing the flow of the molten metal through the ladle opening.
In one example of a method for dislodging a particulate from a ladle storing molten metal, the method includes adding the particulate into a cavity defined by the ladle wherein the particulate obstructs a flow of molten metal from exiting the ladle. The method includes applying vibrational energy to the ladle through a vibrator configured to dislodge the particulate from the ladle allowing the flow of the molten metal to exit the ladle unobstructed by the particulate.
In one example of the method, a slide gate is connected to the ladle and is configured to selectively allow the flow of molten metal to exit the ladle. The method includes opening the slide gate allowing the flow of the molten metal to exit the ladle.
In one example of the method, the slide gate includes a first position and a second position. The second position of the slide gate allowing the flow of the molten metal to exit the ladle and pass through the slide gate. A transfer device is provided and is configured to guide the molten metal exiting the slide gate. The method includes connecting the vibrator to the transfer device. The vibrator is configured to transfer the vibrational energy through the transfer device and the slide gate to the ladle to dislodge the particulate from the ladle allowing the flow of the molten metal to exit the ladle unobstructed by the particulate hen the slide gate is in the second position. The method includes engaging the transfer device with the slide gate. The vibrator is operable to apply the vibrational energy through the transfer device and the slide gate to the ladle to dislodge the particulate, for example sand, from the ladle providing the free flow of molten metal exiting the ladle.
In one example of the method, the vibrator is connected to the slide gate. In alternate example of the method, the vibrator is connected to the ladle.
In one example of the method, the vibrator is configured to generate high frequency vibrational energy. Wherein transferring the vibrational energy further includes transferring or applying high frequency vibrational energy to the ladle to dislodge the particulate from the ladle allowing the flow of molten metal to exit the ladle unobstructed by the particulate.
These and other aspects of the present disclosure are disclosed in the following detailed description of the embodiments, the appended claims and the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.
FIG. 1 is schematic partial cross-sectional front view of one example of a vibratory system for molten metal transfer.
FIG. 2 is an enlarged partial view in the area of A of FIG. 1 shown with the transfer device in a second position and the application of vibrational energy.
FIG. 3A is a schematic cross-sectional view of one example of a slide gate shown in a first position.
FIG. 3B is a schematic cross-sectional view of a slide gate shown in a second position.
FIG. 3C is perspective, cross-sectional view of another example of a slide gate shown in a second position and an example of a ladle.
FIG. 4A is a partial perspective view of another example of the vibratory system for molten metal transfer.
FIG. 4B is an enlarged perspective view of a portion of FIG. 4A.
FIG. 5 is a schematic partial cross-sectional view of an alternate example of the vibratory system for molten metal transfer shown in FIG. 2.
FIG. 6 is a schematic partial cross-sectional view of an alternate example of the vibratory system for molten metal transfer shown in FIG. 2.
FIG. 7 is a schematic partial cross-sectional view of an alternate example of the vibratory system for molten metal transfer shown in FIG. 2.
FIG. 8 is a block diagram of one example of a method for dislodging a particulate from a ladle for storing molten metal.
FIG. 9 is a block diagram of an alternate example of a method for dislodging a particulate from a ladle for storing molten metal.
DETAILED DESCRIPTION
Referring to FIGS. 1-9 examples of a vibratory system, methods for dislodging a particulate from a ladle for storing molten metal, and devices and methods for molten metal transfer are disclosed.
Referring to FIG. 1, an example of a vibratory system for use in transferring molten metal 10 is shown. In the example, the vibratory system 10 is used with, or includes a ladle 14 configured to store molten metal 16. In one example, the molten metal 16 is steel used for a variety of industrial and commercial products. It is understood that vibratory system 10 and methods described herein are also useful for other molten metals, for example aluminum, copper, zinc, tin, titanium, and other metals that are melted and transferred for downstream processes as known by persons skilled in the art. The vibratory system and methods described herein may also be useful for the transfer of materials other than molten metal.
In an alternate example (not shown), the vibratory system 10 is used with devices or receptacles other than ladle 14. In one example, the vibratory system 10 including the vibrator discussed further below may be used with high temperature furnaces commonly used in steel making, as well as other steel mill or foundry equipment that uses particulates to insulate the molten metal from solidifying and temporarily block the flow of molten metals or other molten materials in the manners generally described herein.
Referring to FIG. 1, in one example discussed further below, a particulate 18 is deposited into a bottom of the ladle 14 to prevent premature cooling and solidification of the molten metal 16. As discussed further below, a slide gate 20 is connected to the bottom of the ladle 14 on the exterior of the ladle 14. The slide gate is configured to selectively allow the molten metal 16 to exit the ladle 14.
A tundish or reservoir 24 is positioned downstream of the ladle 14. The tundish receives the molten metal 16 that exits the ladle 14. In the example discussed further below, a transfer device 28 selectively engages with the slide gate 20 and is used to transfer or guide the molten metal 16 from the ladle 14 to the tundish 24.
In the FIGS. 1 and 2 example, a vibrator 30 is connected to or in vibratory communication with the transfer device 28. The vibrator 30 is configured to generate vibrational energy operable to dislodge the particulate 18 positioned in the ladle 14 that may be obstructing, or partially obstructing, a flow 31 (FIG. 2) of the molten metal 16 from the ladle 14 to the tundish 24. As shown in FIG. 2, it is desired that the flow 31 is a free flow condition where the particulate 18 is not obstructing the flow of the molten metal 16 exiting the ladle 14 or the ladle well 35.
In the FIGS. 1 and 2 example, and as best seen in FIGS. 2 and 3A, the ladle 14 defines a cavity 32 to store the molten metal 16 which is received from a blast or metal furnace (not shown). The ladle 14 may be made from cast iron or other materials known by persons skilled in the art. In one example, the ladle 14 includes refractory material 34 which is positioned in the cavity 32 and lines at least a portion of the interior of the ladle 14. In one example, the refractory material 34 includes heat resistant bricks which assist in maintaining the high temperature of the molten metal 16 and prevent premature solidification prior to transfer to the tundish 24. In one example, multiple layers of different types of refractory material 34 may be used. In one example of the refractory material 34 as best seen in FIG. 3C, a layer of insulation 34A is positioned adjacent to an inner surface of the ladle 14. A first layer 34B or safety lining of bricks is positioned on top (toward the interior of the cavity 32) of the insulation 34A, and a second layer 34C or working lining of bricks may be placed on top of the first layer 34B. The refractory material 34 may be constructed in different configurations or layers, and made from materials other than bricks to suit the particular application and performance requirements.
As best seen in FIGS. 2 and 3C examples, the vibratory system 10 is used with or includes a ladle well 35 and a ladle opening 36 defined in the bottom of the ladle 14 in the ladle well 35 to allow the molten metal 16 to exit of flow from the ladle 14 unobstructed by the particulate 18 as further discussed below. The ladle opening 36 is positioned along an axis 38. The position of the ladle opening 36 relative to the ladle 14 may vary to suit the particular application. As best seen in the FIG. 3C example, the ladle opening 36 is defined by a well block 40. In one example, the well block 40 is made from refractory material or a high temperature resistant material, for example ceramic. Other materials, configurations, sizes, shapes and orientations for well block 40 may be used.
As shown in the FIGS. 1 and 2 example, prior to a batch or shot of the molten metal 16 being poured into the cavity 32 of the ladle 14, the particulate 18 is poured or positioned into the bottom of the ladle 14. In one example best seen in FIGS. 1 and 3C, the particulate 18 is positioned in the well block 40 to cover or obstruct the ladle opening 36. Use of the particulate 18 in this manner, at least in part, assists in preventing the high temperature molten metal 16 from cooling in and around the well block 40 and in the ladle opening 36.
In some applications of vibratory system 10, relatively large quantities of particulate 18 may be positioned in the bottom of the ladle 14 in the area described. In one example, approximately 200 pounds of particulate 18 is used for each pour or shot of molten metal 16 that is deposited in the cavity 32 of the ladle 14. Other quantities of particulate 18, higher and lower, may be used to suit the particular application. In one example, the particulate 18 is sand. In applications where the molten metal 16 is steel, different types of sand, or blends thereof, may be used, for example silica, quartz, chromite, zircon, or olivine. It is understood that the particulate 18 may be different materials to suit the particular application and performance requirements.
Referring generally to the FIGS. 1 and 2 example, the vibratory system 10 includes the slide gate 20. The slide gate 20 is configured to selectively allow the molten metal 16 to initially start flowing from the cavity 32 through the ladle well 35 and the ladle opening 36. As best seen in the slide gate 20 examples shown in FIGS. 3A, 3B and 3C, the slide gate 20 includes a body 50 which houses the internal components of the slide gate 20. As best seen in the FIGS. 3A, 3B, 3C example, the slide gate 20 further includes a nozzle 52 having a nozzle upper part 54 including a nozzle upper part opening 55 that is positioned in the ladle opening 36 (e.g., scalingly inside and coaxial with the well block 40) in communication with the cavity 32 of the ladle 14. In one example described above, the particulate 18 is poured or positioned to completely fill or cover, or at least partially fill or cover, the ladle well 35 and the nozzle upper part opening 55 of the nozzle upper part 54 as schematically shown in FIGS. 1, 3A and 3C.
Still referring to the FIGS. 3A and 3C examples, the slide gate 20 includes a nozzle lower part 56 that defines a nozzle lower part opening 57 and includes an outer surface 58. In one example best seen in FIGS. 3A and 3B, the slide gate 20 includes a first plate 60 defining a first passage 62 through the first plate 60. A second plate 64 includes a second passage 66 through the second plate 64 as generally shown. In one example of the slide gate 20, an actuator 78 is connected to the second plate 64 and is configured to selectively and reciprocally move the second plate 64 between a first position (FIG. 3A) and a second position (FIG. 3B). In one example, the actuator 78 is a pressurized pneumatic or hydraulic cylinder or piston. Other types of devices for actuator 78 may be used to suit the particular application.
In the example shown in FIG. 3A, in the first position 80, the second plate 63 is positioned such that the second passage 66 of the second plate 64 and the nozzle lower part opening 57 are not in axial alignment, for example along axis 38, with the first passage 62 of the first plate 60 and the nozzle upper part opening 55 as generally shown. In the first position 80, a portion of the second plate 64 blocks the nozzle upper part opening 55 preventing the flow 31 of molten metal 16 from exiting the ladle 14 and passing through the slide gate 20. In one example, the actuator 78 may position the second plate 64 in the first position 80. In an alternate example (not shown), the slide gate 20 may include a biasing device, for example a spring, that normally biases the second plate 64 to the first position 80.
As best seen in the FIG. 3B example, when it is desired to transfer the molten metal 16 from the ladle 14 to the tundish 24, the actuator 78 (not shown in FIG. 3B) moves the second plate 64 from the first position 80 to the second position 84. In the second position 80, the nozzle upper part 54, the nozzle upper part opening 55 and the first passage 62 are in axial and fluid flow communication with the nozzle lower part 56, the nozzle lower part opening 57 and the second passage 66 as generally shown. In the second position 84, the molten metal 16 has a flow 31 in a free flow, unobstructed by the particulate 18 condition to transfer the molten metal 16 from the ladle 14 and through the slide gate 20 to the tundish 24.
In the flow 31 condition (FIG. 2), the weight and the hydrostatic force of the molten metal 16 positioned in the cavity 32 of the ladle 14 quickly and completely dislodges the particulate 18 from the ladle well 35 and/or bottom part of the ladle 14, and the ladle opening 36 clearing or removing the obstruction to the flow 31, or partial obstruction, caused by the particulate 18. In the flow 31 condition shown in FIG. 2, the particulate 18 passes through the ladle opening 36 and the slide gate 20 along with the molten metal 16. The flow 31 in an unobstructed condition is preferred so the molten material 16 does not prematurely solidify in the ladle 14 and the intended properties (e.g., temperature, material composition, viscosity) of the molten metal 16 are preserved during the transfer to the tundish 24. In one example, the construction and the configurations of the ladle 14 and the slide gate 20 prevent the molten metal 16 from being exposed to the atmosphere (i.e., surrounding air including oxygen) which can have adverse effects on the intended properties and qualities of the molten metal 16.
In an alternate example of the slide gate 20 (not shown), the position of the second plate 64 relative to the first plate 60 is variable to create or allow a flow 31 of the molten metal 16 that is not at a maximum or free flow rate or condition. In other words, the actuator 78 may move the second plate 64 such that the opening 57 of the nozzle lower part 56 only partially overlaps the opening 55 of the nozzle upper part 54. In one example, the actuator 78 may first move the second plate 64 to the second position 84 to allow a maximum flow of molten metal to exit the ladle 14 and clear the particulate 18 from the ladle well 35, but thereafter move the second plate 64 to a position other than the second position 84 such that a reduced flow of molten metal 16 is allowed to exit the ladle 14. It is understood that the second position 84 may be any position between the first position 80 and the second position 84 (as shown in FIGS. 2 and 3B. In other words, the second position 84 includes positions of the slide gate 20 wherein at least some flow 31 of the molten metal 16 is passing through the slide gate 20.
In the examples shown in FIGS. 1, 2 and 3C, the slide gate 20 is rigidly connected to the exterior of the bottom part of the ladle 14 as generally shown. In alternate configurations (now shown), the slide gate 20 may be positioned on the transfer device 28 discussed below, or other mechanisms, that move and position the slide gate 20 to engage the ladle 14 and position the slide gate 20 and the nozzle upper part 54 in communication with the ladle opening 36 as generally described and illustrated. Alternate configurations, components, sizes, shapes, and connection or engagement schemes to the ladle 14 of the slide gate 20 may be used to suit the particular application and performance requirements as known by persons skilled in the art.
Referring to the FIGS. 1 and 2 examples of the vibratory system 10, the transfer device 28 is used to transfer or guide the molten metal 16 passing through the slide gate 20 to the tundish 24. In one example, the transfer device 28 defines a passage 86 and is configured to selectively engage the slide gate 20 allowing the molten metal 16 to exit from the slide gate 20 through the passage 88 of the transfer device 28. In one example, the transfer device 28 includes a first position 87 (FIG. 1) wherein the transfer device 28 is disengaged from the slide gate 20, and a second position 88 (FIG. 2) wherein the transfer device 28 is engaged with the slide gate 20 and is configured to guide the flow 31 of the molten metal 16 through the passage 86 of the transfer device 28. For purposes of illustration only, FIG. 1 also shows in dashed lines the second position 88 of the transfer device 28 which when the slide gate 20 is placed in the second position 84 allows for the illustrated flow 31 of the molten metal 16 also shown in dashed line. In the FIG. 1 example, if the transfer device 28 is positioned in the first position 87 (disengaged from the slide gate 20), the vibrational energy discussed further below would not transfer or be in communication with the ladle 14 (vibrational energy shown in FIG. 1 in dashed line above or upstream of the transfer device 28).
In one example schematically shown in FIGS. 1 and 2 and alternate example shown in FIGS. 4A and 4B, the transfer device 28, 28A (referred hereafter simply as 28 unless otherwise noted) includes an articulatable arm 90 and a shroud 94 that is connected to the articulatable arm 90. The shroud 94 is configured to engage the slide gate 20 when the transfer device 28 is in the second position 88 as best seen in FIG. 2. In the example, the shroud 94 defines the passage 86 of the transfer device 28 as described above.
As best seen in the FIG. 1 example, the articulatable arm 90 includes a base 98 that is rigidly secured and stationary. A first arm 100 is connected to the base 98. In one example, the first arm 100 is rotatably connected to the base and rotatably moves about a first axis of rotation 104 relative to the base 98. A second arm 108 is connected to the first arm 100. In one example, the second arm 108 is rotatably connected to the first arm 100 and rotatably moves about a second axis of rotation 110 relative to the first arm 100. In one example the transfer device 28 includes a lift device (not shown) which is operable selectively and reciprocally raise and lower the first arm 100 and/or the second arm 108 in a vertical direction 114 to achieve the first position 87 and the second position 88 of the transfer device 28 relative to the slide gate 20 as described above.
In an alternate example (not shown) the first arm 100 is rigidly fixed to the base 98 and the second arm 108 rotates about the second axis of rotation 110 relative to the first arm 100. In an alternate example (not shown), the first arm 100 rotates about the first axis of rotation 104 relative to the base 98 and the second arm 108 is rigidly fixed to the first arm 100 (i.e., the second arm 108 does not rotate relative to the first arm 100). In one example of the transfer device 28, actuators (not shown) are used to rotate the first arm 100 relative to the base 98 and the second arm 108 relative to the first arm 100. In one example, one or more pneumatic or hydraulic cylinders or pistons may provide the lifting and lowering of the transfer device along the vertical direction 114 relative to the base 98 and slide gate 20.
Referring to FIGS. 4A and 4B, an alternate example of the transfer device 28A and the articulatable arm 90A are shown. In the example, the first arm 100 and the second arm 108 are included and are generally described above. A third arm 115 is rotatably connected to the base 98 about an axis of rotation. A fourth arm 116 is rotatably connected to the third arm 115 about an axis of rotation and is connected to the first arm 100. Actuators may be used to rotate the third arm 115 and/or the fourth arm 116 relative to the base 98 and the connected arms as described above. A lift device may be used to move the shroud 94 in a vertical direction 114 as described above. Alternate components, constructions, configurations, and movements for the articulatable arm 90, 90A and the transfer device 28, 28A may be used to suit the particular application as known by those skilled in the art.
In one example, the vibratory system 10 includes a control system 118 (schematically shown in FIG. 1). The control system 118 is in communication with the actuators to initiate and control movement of the actuators described to move and position the transfer device 28 between the first position 87 and the second position 88 relative to the slide gate 20 as described above and further below. In one example, the control system 118 includes a processor (e.g., a computer or central processing unit (CPU)), a memory device to store software and programs executable by the processor, controllers to send and receive signals to the actuators, and input and output devices (e.g., human machine interface (HMI)), for example display screens, keyboards and other devices used by operators to monitor and control movement of the transfer device. The control system 118 may also serve to supply electrical power, and other services, for example suppling pressurized air or hydraulic fluid from other supply sources, for the described actuators. The control system 118 may also be used to monitor and control movement of the slide gate 20 as described above. Alternate configurations, components, hardware, software, and functions of the control system 118 may be used to suit the particular application as known by persons skilled in the art.
In one example as best seen in FIGS. 1, 2 and 4A, the shroud 94 includes a pipe 126 including a first end 130 and a second end 132. The shroud 94 defines the passage 86 of the transfer device 28. A receiver 136 is connected to, or integral with, the pipe 126 at the first end 130 as generally shown. In use, the second end 132 is positioned in the tundish 24. In one example, the shroud 94 is made from steel or cast iron and is rigidly connected to the second arm 108.
As best seen in the FIG. 4A alternate example, the shroud 94 may be connected to the second arm 108 by a yoke 138 connected to the end of the second arm 108. In the FIG. 4A example, the yoke 138 is connected to a collar 139 that is positioned around the pipe 126. The collar 139 is sized to allow the collar 139 (and connected yoke 138 and second arm 108) to axially move relative to the pipe 126, but is sized to prevent the collar 139 from passing over the receiver 136 (i.e., the inner diameter of the collar 139 is smaller than an outer diameter of the receiver 136). This configuration allows the articulating arm 90 to position the receiver 136 of the shroud 94 into firm, abutting engagement of the receiver 136 with the nozzle lower part outer surface 58 as shown in FIG. 2. In an alternate example, the shroud 94 may be connected to the second arm 108 allowing different movement of the shroud 94 relative to the second arm 108 (e.g., relative rotation or linear movement).
Referring to the FIGS. 1, 2, 4A and 4B examples of the vibratory system 10, the vibrator 30 is connected to the transfer device 28. In the FIG. 2 example, the vibrator 30 is connected to the articulatable arm 90 to generate and transfer a vibrational energy 140 to dislodge the particulate 18 when the transfer device 28 is in the second position 88 and the shroud 94 is engaged with the slide gate 20. In the example shown in FIGS. 1, 2, 4A and 4B, the vibrator 30 is connected to the second arm 108 of the articulatable arm 90. The vibrator 30 may be connected at alternate positions of the articulatable arm 90, for example on the first arm 100 or at alternate positions along the second arm 108 than as shown. It is understood that the vibrator 30 may be connected to the shroud 94 (e.g., the pipe 126 (FIG. 5), or the receiver 136), the slide gate 20 (FIG. 6), the ladle 14 (FIG. 7), or other components of the vibration system 10 described or illustrated herein.
In one example, the vibrational energy 140 has a frequency between 4900 vibrations per minute (VPM) to 42,000 vibrations per minute (VPM). In an alternate example, the vibrational energy 140 has a frequency between 7300 VPM to 28,000 VPM. In one example described further below, the vibrator 30 is a pneumatic rotary vibrator. It is understood that the disclosed frequencies may be used for any of the examples or configurations of the vibration system 10 or methods to dislodge particulate from a ladle for storing molten metal described or illustrated herein.
In one example, the vibrator 30 is a pneumatic rotary vibrator that uses pressurized air that is applied to one or more masses positioned inside a housing or casing of the vibrator 30. The mass (e.g., a turbine wheel, ball, roller, motor driven eccentric) may be unbalanced or the enclosure housing the mass may be of eccentric configuration creating an unbalanced mass. In one example, on application of pressurized air to the mass, the unbalanced mass moves or rotates thereby applying a centrifugal force to the casing to produce a sinusoidal wave of energy generating the rotational vibration (i.e., vibration energy 140). In one example of a pneumatic rotary vibrator, the frequency and the centrifugal force can be regulated and changed by the pressurized air provided to vary the frequency and magnitude of the vibrational energy 140 produced by the vibrator 30. In one example, the frequency can be within a range of about 4900 vibrations or revolutions per minute (VPM) to 42,000 VPM and an impact or centrifugal force range of about 60 force pounds (lbf.)(288 Newtons (N)) to 1600 (lbf.) (7131 Newtons (N)).
In one example, the vibrator 30 is a pneumatic high frequency rotary vibrator configured to generate the vibrational energy 140 at a high frequency. In one example, the vibrational energy 140 generated at a high frequency is between about 7,300 VPM and 27,900 VPM. In one example, the centrifugal force or force generated may be between about 312 force pounds (lbf.)(1389 N) and 1,314 lbf. (5,845 N). In one example, the frequency of the vibrational energy 140 is between 22,740-27840 VPM and the force generated is between 312 lbf. (1,389 N) and 468 lbf. (2,082 N). In another example, the frequency of the vibrational energy 140 is between 15,740 VPM and 20,060 VPM, and the force generated is between 489 lbf. (2174 N) and 794 lbf. (3,530 N). In another example, the frequency of the vibrational energy 140 is between 11,920 VPM and 14,760 VPM, and the force generated is between 494 lbf. (2197 N) and 757 lbf. (3,369 N). In another example, the frequency of the vibrational energy 140 is between 7,360 VPM and 10,240 VPM, and the force generated is between 377 lbf. (1,676 N) and 729 lbf. (3,243 N). In another example, the frequency of the vibrational energy 140 is between 11,000 VPM and 13,980 VPM, and the force generated is between 813 lbf. (3,618 N) and 1,314 lbf. (5,845 N).
In an alternate example, the vibrator 30 may be a pneumatic linear vibrator. In one example that linear vibrator includes a freely oscillating differential pressure piston. In one example, the piston is caused to impact a plate configured to create a repetitive hammer or impact effect generating the vibrational energy 140. The linear vibrator example can be low frequency or high frequency and include a centrifugal or linear force operable to dislodge the particulate 18 positioned in the ladle 14 obstructing the flow 31 of the molten metal 16 through the ladle opening 32.
In an alternate example, the vibrator 30 may be a pneumatic impactor type of device resulting in the generation of the vibrational energy 140 operable to dislodge the particulate 18 positioned in the ladle 14 obstructing the flow 31 of the molten metal 16 through the ladle opening 32. In one example the pneumatic impactor (i.e., the vibrator 30) imparts a hammer-type blow to the component it is attached to, for example the ladle 14 (see example in FIG. 6), the shroud 94 (see example in FIG. 5), or the articulatable arm 90. The frequency of the pneumatic impactor can be single controlled strikes/impacts, to very low frequency, to high frequency.
In an alternate example, the vibrator 30 is an electric type of vibrator. In an alternate example, the vibrator 30 is a hydraulic type of vibrator.
It is understood that the vibrator 30 can take other forms, configurations, variances in frequencies (VPM), variances in centrifugal, linear and impact forces (lbf. or N) applied, and the types of vibration devices or motors, to generate the vibrational energy 140 operable to dislodge the particulate 18 positioned in the ladle 14 or ladle well 35 allowing the flow 31 of the molten metal 16 to exit through the ladle opening 36 unobstructed by the particulate 18dle opening 36 as described, and/or to suit the particular application and performance requirements as known by persons skilled in the art. Although one vibrator 30 is illustrated, it is understood that different numbers of the vibrator 30 may be used, for example two or more vibrators that are positioned in alternate or different areas of the transfer device 28, the articulatable arm 90, the shroud 94, the slide gate 20, and/or the ladle 14.
Referring to the FIGS. 1 and 2 example, the vibratory system 10 includes a supply line 146 connected to and in communication with the vibrator 30 and the control system 118. In one example, the supply line 146 is configured to provide electrical power to the vibrator 30. In another example, the supply line 146 alternately, or in addition to the electrical power, further provides service connections, for example, a pressurized air line or conduit to provide pressurized air to the vibrator (e.g., for example when the vibrator 30 is a pneumatic rotary vibrator as described above). In an alternate example, the supply line 147 may be a hydraulic fluid line or conduit in communication with a hydraulic pump. In alternate examples, the supply line may provide alternate service functions or materials, for example electronic communication cables configured such that the control system 146 can send digital or electronic signals to, and receive from, the vibrator 30 (and/or sensors in communication with the vibrator 30), to monitor and control the operation of the vibrator 30. Other connections or services may be included in supply line 146 as known by persons skilled in the art.
In one example of the vibratory system 10, the control system 118 includes sensors (not shown) and other devices (not shown) which are connected to and in communication with the vibrator 30. In one example, the control system 118 monitors the state or condition of the vibrator 30 and operation metrics, for example, the speed, revolutions or vibrations per minute (VPM), the air pressure and volumetric flow of air being provided to the vibrator 30, and other metrics known by persons skilled in the art. In one example, the control system 118 regulates and controls the described services of supplies to the vibrator 30, for example controlling the volumetric flow and pressure of pressurized air being supplied to the vibrator 30.
The control system 118 may include additional sensors, for example to monitor or determine if a condition exists that the particulate 18 has formed an obstruction of the flow 31 in the ladle 14, or a condition that the particulate 18 is not forming an obstruction of the flow 31 in the ladle 14 and there is a condition or state of unobstructed or free flow of the molten metal 16 exiting the ladle 14 or passing through the slide gate 20. In one example, based on detection and output of a sensor, the control system may generate an output, for example an alarm or audible or visual indicator to an operator that the particulate has formed an obstruction in the flow 31 so the operator can activate the vibrator 30 to initiate generation of the vibratory energy 140 to dislodge the particulate 18.
In one example, the control system 118 may be configured to detect an obstruction by the particulate 18 and automatically activate the vibrator 30 to dislodge the particulate 18 according to preprogrammed instructions in the control system 118. In an alternate example, the control system 118 may be configured to alter or adjust the operation of the vibrator 30 based on information, states, or conditions detected and communicated by a sensor. In one example, where the vibrator 30 is generating the vibratory energy 140 but the control system detects through a sensor that the particulate 18 continues to form an obstruction (i.e., the vibratory energy 140 has not dislodged the particulate 18 from the ladle 14), the control system 118 may be configured to automatically adjust the operation of the vibrator 30 based on preprogrammed instructions. In one example, the control system may increase or decrease the pressure of the pressurized air, or the volumetric flow of pressurized air, that is being supplied to the vibrator 30 to change the frequency of the vibratory energy and/or the force of the vibratory energy 140 to the transfer device 28, the slide gate 20, or the ladle 14. The control system 118 may also be configured for these changes to be manually initiated by an operator. Other features and functions of the control system 118 in relation to the vibrator 30 and vibratory system 10 may be included as known by persons skilled in the art.
Referring to FIG. 5, an alternate example of the vibratory system 10A is shown. In the example, the same reference numbers represent the same components and functions as previously described and illustrated.
In the FIG. 5 example, the vibrator 30 is connected to the shroud 94. The vibrator 30 is operable to generate and transfer the vibrational energy 140 to dislodge the particulate 18 allowing the molten metal 16 to exit the ladle 14 unobstructed by the particulate 18 when the transfer device 28 is in the second position 88 and the shroud 94 is engaged with the slide gate 20 as generally shown and described above. The vibrator 30 may be of any of the types or forms of vibrators 30 discussed above and may be positioned at alternate locations on the shroud 94. The vibrator 30 also includes a supply line 146 (not shown in FIG. 5) in communication with the control system 118 as described above. It is understood that the location of the vibrator 30 shown in FIG. 5 may be used with any of the configurations or variations of the vibratory system 10 described herein.
Referring to FIG. 6, an alternate example of the vibratory of vibratory system 10B is shown. In the example, the same reference numbers represent the same components and functions as previously described and illustrated.
In the FIG. 6 example, the vibrator 30 is connected to the slide gate 20. The slide gate 20 includes a first position 80 wherein the slide gate 20 prevents the flow 31 of the molten metal 16 through the slide gate 20 and a second position 84 wherein the slide gate 20 allows the flow 31 of the molten metal 16 through the slide gate 20. The vibrator 30 is configured to generate and transfer the vibrational energy 140 to the ladle 14 to dislodge the particulate 18 when slide gate 20 is in the second position 84 allowing the flow 31 of the molten metal 16 to exit the ladle 14 unobstructed by the particulate 18. In the example, the transfer device 28 is positioned in the second position 88 and the shroud 94 is engaged with the slide gate 20 as generally shown.
In an alternate example of FIG. 6 (vibrator 30 connected to the slide gate 20), the vibrator 30 is configured to generate and transfer the vibrational energy 140 to the ladle 14 to dislodge the particulate 18 when the transfer device 28 is in the first position 87. In this example, the vibrator 30 may be used in a manner to deter or prevent the particulate 18 from forming an obstruction to the flow 31. In other words, by generating the vibratory energy 140 prior to moving the slide gate 20 to the second position 84, and thus shaking or vibrating the particulate 18 before the flow 31 has started, this may prevent or deter the particulate 18 from forming the obstruction.
In the FIG. 6 example, the vibrator 30 may be of any of the types or forms of vibrators 30 discussed above. The vibrator 30 also includes a supply line 146 (not shown in FIG. 6) in communication with the control system 118 as described above. It is understood that the location of the vibrator 30 shown in FIG. 6 may be used with any of the configurations or variations of the vibratory system 10 described herein.
In the FIG. 6 example as shown with the vibrator 30 connected to the slide gate 20, the transfer device 28 is not needed to support the vibrator 30 or transfer the vibrational energy 140 to dislodge the particulate 18 and may not form part of the vibratory system 10 (shown in phantom line). It is understood that the transfer device 28 may be used as described above and form part of the vibratory system 10.
Referring to FIG. 7, an alternate example of the vibratory system 10C is shown. In the example, the same reference numbers represent the same components and functions as previously described and illustrated.
In the FIG. 7 example, the vibrator 30 is connected to the ladle 14. The vibrator 30 is configured to generate and transfer the vibrational energy 140 to the ladle 14 to dislodge the particulate 18 allowing the flow 31 of the molten metal 16 to exit the ladle 14 unobstructed by the particulate 18. In the example, the transfer device 28 is in the second position 88 and the shroud 94 is engaged with the slide gate 20 as generally shown. In an alternate example, the vibrator 30 is operable to generate and transfer the vibrational energy 140 to the ladle 14 to dislodge the particulate 18 when the transfer device 28 is in the first position 87. In this example, the vibrator 30 may be used in a manner to deter or prevent the particulate 18 from forming an obstruction to the flow 31. In other words, by generating the vibratory energy 140 prior to moving the slide gate to the second position 84, and thus shaking or vibrating the particulate 18 before the flow 31 has started, this may prevent or deter the particulate 18 from forming the obstruction.
In the FIG. 7 example, the vibrator 30 may be of any of the types or forms of vibrators 30 discussed above. The vibrator 30 also includes a supply line 146 (not shown in FIG. 7) in communication with the control system 118 as described above. It is understood that the location of the vibrator 30 shown in FIG. 7 may be used with any of the configurations or variations of the vibratory system 10 described herein.
In the FIG. 7 example as shown with the vibrator 30 positioned on the ladle 14, the transfer device 28 is not needed to support the vibrator 30 or transfer the vibrational energy 140 to dislodge the particulate 18 and may not form part of the vibratory system 10 (shown in phantom line). It is understood that the transfer device 28 may be used as described above and form part of the vibratory system 10. It is further understood that in this example, the slide gate 20 is not needed to support the vibrator 30 or transfer the vibrational energy 140 to dislodge the particulate 18 and may not form part of the vibratory system 10. It is understood that the slide gate 20 may be used as described above and form part of the vibratory system 10.
Although the vibratory system 10 has been described in variations as vibratory system 10A, 10B, and 10C, it is understood that alternate variations, configurations, and components of the vibratory system 10 may be made within the disclosure and additional variations thereof as known by persons skilled in the art.
Referring to FIG. 8 an example of a method 200 for dislodging the particulate 18 from the ladle 14 or the ladle well 35 for storing molten metal 16 is shown. In the example the same reference numbers represent the same components and functions as previously described and illustrated.
In one example, the method 200 includes a step 205 of adding the particulate 18 into the cavity 32 of the ladle 14 wherein the particulate 18 obstructs the flow 31 of the molten metal 16 from exiting the ladle 14. As described in the example above, the particulate 18 may be deposited or positioned to fill or cover the ladle well 15 and/or the ladle opening 36. In one example wherein the molten metal 16 is steel, the particulate 18 may be sand in the form, or alternate materials and/or blends, described above. As noted above, alternate forms or materials of particulate 18 may be used and the placement or deposit of the particulate 18 in the ladle 14 may vary to suit the particular application.
Step 210 includes applying vibrational energy 140 to the ladle 14 through the vibrator 30 configured to dislodge or disrupt the particulate 18 from the ladle 14 (including the ladle well 35) allowing the flow 31 of the molten metal 16 to exit the ladle 14 unobstructed by the particulate 18. In the example, the molten metal 16 exits the ladle when the slide gate 20 is moved from the first position 80 (i.e., closed in FIG. 3A) to the second position 84 (i.e., opened for example as shown in FIG. 3B), or to a position therebetween as described above. As described above, the flow 31 is intended to be a free flow (i.e., unobstructed by the particulate 18) out of the ladle 14 and through the slide gate 20. The vibrator 30 and the alternate placements on the transfer device 28, the shroud 94, the slide gate 20, and/or the ladle 14 are described and illustrated above.
Referring to FIG. 9, an alternate method 200A for dislodging the particulate 18 from the ladle 14 for temporarily storing molten metal 16 (including the ladle well 35) and transferring the molten metal 16 is shown. Steps using the same reference numbers include the same steps and components as previously described and illustrated.
In the FIG. 9 example, step 205 is included adding the particulate 18 into the cavity 32 of the ladle 14 as described.
In the method 200A example, the transfer device 28 is provided and configured to guide the molten metal 16 exiting the slide gate 20 as described and illustrated above. In step 207, the transfer device 28 is selectively engaged with the slide gate 20 forming the passage 86 for the molten metal 16 to flow from the ladle 14 to the tundish 24 when the slide gate 20 is actuated to move from the first position 80 to the second position 84. In one example, the transfer device 28 reciprocally moves between the first position 87 and the second position 88 to selectively engage and disengage the shroud 94 from the slide gate 20 as described above.
In one example, connecting the vibrator 30 to the transfer device 28 is included. In another example, connecting the vibrator 30 to the articulatable arm 90 is included. In one example shown and described in FIGS. 1, 2, 4A and 4B, the vibrator 30 is connected to the second arm 108 of the articulatable arm 90. In alternate examples described above, the vibrator 30 can alternately be connected to different portions of the transfer device 28, for example the first arm 100, or the shroud 94. In an alternate example described above, the vibrator 30 may alternately be connected to the slide gate 20. In an alternate example described above, the vibrator 30 may alternately be connected to the ladle 14.
The example of method 200A includes the step 208 previously described. In the example, the vibrator 30 is configured to generate and transfer the vibrational energy 140 through the transfer device 28 and the slide gate 20 to the ladle 14 to dislodge the particulate 18 from the ladle 14 allowing the flow 31 of the molten metal 16 to exit the ladle 14 unobstructed by the particulate 18 when the slide gate 20 is in the second position 84. In the FIG. 9 example, step 208 of applying the vibrational energy 140 is initiated prior to opening the slide gate 20 (i.e. the slide gate 20 is in the first position 80 preventing flow 31 of the molten metal 16 from the ladle 14).
In the method 200A example, following the generating and applying the vibrational energy 140, step 210 includes opening the slide gate 20 allowing the flow 31 of the molten metal 16 to exit the ladle 14 as described above. In the slide gate 20 example described above, the actuator 78 moves the second plate 64 from the first position 87 to the second position 84 allowing for the flow 31 of the molten metal 16 to flow through the slide gate 20 into the shroud 94. As described above, applying the vibrational energy 140 to the ladle 14 dislodges or disrupts the particulate from the ladle 14 (e.g., the ladle well 35) allowing the molten metal 16 and the dislodged particulate 18 to flow through the shroud 94 as described above.
In an alternate example (not shown), the step 208 of generating and applying the vibrational energy 140 by the vibrator 30 may be initiated after step 210 (opening the slide gate). In the example, it may be necessary to only apply the vibrational energy 140 to the ladle 14 (e.g., through the transfer device 28, shroud 94, and/or the slide gate 20 depending on positioning of the vibrator 30) if it is first determined that there is an obstruction or blockage preventing the molten metal 16 to flow from the ladle 14. In the example, once an obstruction or blockage is determined to exist, the control system 118 can be used to activate the vibrator 30 to generate and apply the vibrational energy 140 to dislodge the particulate 18 and clear the blockage. Through use of the control system 118, the frequency and/or magnitude of the impacts of the vibrational energy 140 may be varied as described above.
The vibrator 30 may be configured in any of the frequencies and impact forces described above to suit the particular application in order to dislodge the particulate 18 from the ladle 14 described above.
It is understood that additional steps may be added, or removed, for the example methods 200 and 200A described above to suit the particular application and performance requirements. It is also understood that the method steps may take place in a different time or sequential order to suit the particular application and performance requirements.
While the invention has been described in connection with certain embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
Patent Application
20240165698
