Mold handling system

Abstract

A mold handling manufacturing line is provided, comprising at least a first subline and a second subline. The mold handling manufacturing line moves at least one mold carriage supporting a casting mold for forming a casting part. The mold handling manufacturing line comprises at least a first subline and a second subline, and a first conveying station. The first conveying station communicates with the first subline and the second subline. The second subline is arranged substantially parallel to and spaced apart from the first subline. The first conveying station includes a conveying cart configured to receive the at least one mold carriage. The first conveying station includes a servo belt drive line comprising a servo motor that rotates one or more drive pulleys via a belt coupled to the conveying cart.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application is related to and claims priority from U.S. Provisional Patent Application No. 63 / 470,586, entitled "Mold Handling System," filed on June 2, 2023. The subject matter disclosed in the provisional application is hereby expressly incorporated by reference herein.

[0002] [Technical Field] The present disclosure relates to manufacturing lines for cast parts, and more particularly to a mold handling manufacturing line that moves a mold carriage in an improved manner along the manufacturing line.

Background Art

[0003] Cast parts, particularly those made from molten metal (such as water valves and couplings), are often formed within a sand mold (a sand casting mold). Such sand molds typically consist of two halves, each forming half of the image of the folded part. When these two halves are joined, their images form a cavity in the shape of the fully formed part. A passage extends from the cavity of the sand mold to the outside. This allows molten metal to be poured into the sand mold to form the part. When this occurs, the molten metal is allowed to cool and solidify. After solidifying, the part is typically removed from the sand mold for further processing. The sand mold is broken, and the sand is recycled to create a new sand mold for another part.

[0004] A cast parts manufacturing line is a known method for mass-producing such parts. This manufacturing line includes a first station where the mold is created, a second station where molten metal is poured into the mold, and a third station where the cast parts are removed and the sand is recycled. To transport the sand molds to and from the stations, the sand molds are placed on mold trolleys that run along a rail line. In addition to movement between these stations, the rail line also serves the need for the molten metal to solidify and cool, which takes time. Therefore, the rail line creates long routes, particularly between the station where the molten metal is poured and the station where the cast parts are removed. The mold trolleys are moved along this rail line via two mechanisms, either adjacent mold trolleys or actuators. When one mold trolley is moved while the rail line is substantially full with mold trolleys lined up sequentially, it pushes adjacent mold trolleys, which in turn push further adjacent mold trolleys, and so on. This creates a chain reaction that constantly moves or indexes (slides) the mold carriages. Furthermore, to save space on the manufacturing floor, the tracks can be divided into multiple sub-lines (branch lines). Actuators are used to move the mold carriages from one sub-line to another, and to move the mold carriages onto a sub-line to initiate the movement of adjacent mold carriages.

[0005] Multiple transport stations connect multiple sublines. An actuator at a transport station moves a mold cart from one subline to another. At the same time, another actuator moves the mold cart from the transport station onto the subline. When this occurs, the mold cart that has been moved onto the subline pushes adjacent mold carts, and the latter pushes further adjacent mold carts. This creates a chain reaction, moving each mold cart on the subline by one position (i.e., indexing / sliding). At the end of the subline, the last mold cart is pushed onto another transport station by an actuator. This transport station moves the mold cart to the next subline. Then, another actuator moves the mold cart from the transport station onto this new subline. And again, the mold cart pushes adjacent mold carts, and the latter pushes further adjacent mold carts. This process continues throughout the entire manufacturing line.

[0006] Such a manufacturing line may include more than 100 mold carts, each of which is actively indexed (slid) along a sub-line at any given time. The time required to move the mold carts, particularly the time from when the molten metal is poured into the mold until the cast part is removed, is considered sufficient to allow the part to cool and solidify.

[0007] A problem with such manufacturing lines is that sand molds are relatively fragile. Multiple mold carts move between sub-lines and come into contact with each other as they index (slide) along the sub-lines, which can damage the shape of the cavity both before and after molten metal is poured into the sand mold. Sudden starts, stops, and impacts can cause one half of the sand mold to shift relative to the other. This poses a risk of compromising the integrity of the molding cavity shape, and therefore, a risk of damaging the molded part.

[0008] The potential cause of such sudden starts and stops lies in how the actuators operate to move the mold carriage. These actuators are hydraulically driven, which results in relatively immediate starts and stops. As a result, one half of the mold may stop or start earlier than the other half (see Figures 2 through 8). When moved by these actuators, the sudden starts and stops of the mold carriage can displace the sand and damage the components. [Overview of the project]

[0009] Accordingly, one exemplary embodiment of the present disclosure provides a mold handling manufacturing line comprising a first subline, a second subline, a third subline, a fourth subline, a first conveying station, and a second conveying station. The second subline is arranged substantially parallel to and spaced apart from the first subline. The third subline is arranged substantially parallel to and spaced apart from the first and second sublines. The fourth subline is arranged substantially parallel to and spaced apart from the first, second and third sublines. The first conveying station communicates with the fourth subline and the first subline and includes a conveying cart configured to receive the at least one mold trolley. The first transport station is positioned substantially centered relative to the first transport station and includes a servo belt drive line comprising a servo motor that rotates one or more drive pulleys via a belt, the belt being coupled to the transport cart, and when the servo motor rotates in a first rotational direction, this causes the belt, positioned on the one or more drive pulleys, to move the transport cart in a first linear direction between the fourth subline and the first subline, and when the servo motor rotates in a second rotational direction, this causes the belt, positioned on the one or more drive pulleys, to move the transport cart in a second linear direction between the fourth subline and the first subline. The second transport station is positioned distal to the first transport station. The second transport station communicates with the first subline, the second subline, the third subline and the fourth subline and includes a first transport cart configured to receive at least one mold cart and a second transport cart configured to receive at least one other mold cart. As part of the second transport station, a servo actuator moves the rod in the first linear direction and the second linear direction.The rod is attached to the first transport cart of the second transport station and the second transport cart of the second transport station, so that when the rod moves in the first linear direction and the second linear direction, both the first transport cart of the second transport station and the second transport cart of the second transport station can move in the first linear direction and the second linear direction. This allows the first transport cart of the second transport station to move between the first subline and the second subline, and the second transport cart of the second transport station to move between the third subline and the fourth subline.

[0010] In the embodiments described above and other embodiments, the one or more drive pulleys of the first transport station may include a first pulley and a second pulley, wherein the first pulley may be spaced a certain distance from the second pulley, and the distance may be at least the travel length of the first transport cart. Furthermore, in the embodiments described above and other embodiments, when the servo motor rotates in the first rotational direction, this causes the belt positioned on the one or more drive pulleys to move the transport cart in the first linear direction to the fourth subline, and when the servo motor rotates in the second rotational direction, this causes the belt positioned on the one or more drive pulleys to move the transport cart in the second linear direction to the first subline. Furthermore, the mold handling manufacturing line may further include an index actuator operating adjacent to the first transport station and the first subline, the index actuator may include a servo actuator that rotates to move a rod attached to an index block, the dog may be rotatable about a pivot pin on the index block, the dog may be biased in a first rotational direction, and a stopper may be engageable with the dog to restrict the dog's movement in the first rotational direction, the servo actuator may rotate to extend the index block when the transport cart of the first transport station is positioned adjacent to the first subline, and the dog may be configured to engage with the at least one mold trolley to pull the at least one mold trolley from the transport cart of the first transport station onto the first subline. Furthermore, the mold handling manufacturing line may further include an index actuator operating adjacent to the second transport station and the second sub-line, the index actuator may include a servo actuator that rotates to move a rod attached to an index block, the dog may be rotatable about a pivot pin on the index block, the dog may be biased in a first rotational direction, and a stopper may be engageable with the dog to restrict the dog's movement in the first rotational direction, the servo actuator may rotate to extend the index block when the first transport cart of the second transport station is positioned adjacent to the second sub-line, and the dog may be configured to engage with the at least one mold trolley to pull the at least one mold trolley from the transport cart of the second transport station onto the first sub-line. Furthermore, the mold handling manufacturing line may further include an index actuator operating adjacent to the second transport station and the fourth subline, the index actuator may include a servo actuator that rotates to move a rod attached to an index block, the dog may be rotatable about a pivot pin on the index block, the dog may be biased in a first rotational direction, and a stopper may be engageable with the dog to restrict the dog's movement in the first rotational direction, the servo actuator may rotate to extend the index block when the second transport cart of the second transport station is positioned adjacent to the fourth subline, and the dog may be configured to engage with another at least one mold trolley to pull the other at least one mold trolley from the transport cart of the second transport station onto the fourth subline. Furthermore, in the embodiments described above and other embodiments, the servo actuator of the second transport station is capable of rotating a ball screw, the ball screw being capable of linearly moving the rod, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this is capable of linearly moving the ball nut and the thrust tube with the first transport cart of the second transport station and the second transport cart of the second transport station attached. Furthermore, in the embodiments described above and other embodiments, the servo actuator of the index actuator can rotate a ball screw, the ball screw can move the rod linearly, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this may move the ball nut and the thrust tube linearly with the index block attached. Furthermore, the mold handling manufacturing line may further include a third transport station located distal to the second transport station, the third transport station may communicate with the second sub-line and the third sub-line, and the third transport station may include a transport cart configured to receive at least one mold trolley, and as part of the third transport station, a servo actuator may move a rod in a first linear direction and a second linear direction, the rod may be attached to the transport cart of the third transport station, so that when the rod moves in the first linear direction and the second linear direction to move the transport cart of the third transport station between the second sub-line and the third sub-line, the transport cart of the third transport station may be movable in the first linear direction and the second linear direction. Furthermore, in the embodiments described above and other embodiments, the servo actuator of the third transport station is capable of rotating a ball screw, the ball screw being capable of moving the rod linearly, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this is capable of moving the ball nut and the thrust tube linearly with the transport cart of the third transport station attached. The mold handling manufacturing line may further include a jacket lift assembly configured to place a mold jacket above a mold on at least one mold trolley, the jacket lift assembly may include one or more jacket lift arms, and the jacket lift assembly may include a frame-mounted extendable rod attached to the one or more jacket lift arms, the servo actuator being attached to the one or more jacket lift arms to extend or retract the one or more jacket lift arms. Furthermore, in the embodiments described above and other embodiments, the servo actuator of the jacket lift assembly can rotate a ball screw, the ball screw can move the rod linearly, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this may cause the ball nut and the thrust tube to move linearly with the frame of the jacket lift assembly attached. The mold handling manufacturing line may further include a sand push-off station configured to remove the sand mold from the at least one mold trolley, the sand push-off station may include a jacket lift actuator assembly and a push-off actuator assembly, the jacket lift actuator assembly may include a jacket lift servo actuator configured to selectively raise and lower one or more jacket lift arms via a frame to remove the jacket before removing the sand from the mold on the at least one mold trolley, the push-off actuator assembly may include a push-off servo actuator having an extendable rod for moving the jacket lift actuator assembly, and after the jacket lift actuator assembly has lifted the jacket from the mold, the push-off servo actuator may be configured to move the jacket lift actuator assembly and the mold seated on the at least one mold trolley. Furthermore, in the embodiments described above and other embodiments, the push-off servo actuator of the push-off actuator assembly is capable of rotating a ball screw, the ball screw being capable of linearly moving the rod, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this may cause the ball nut and the thrust tube to move linearly with the frame of the push-off actuator assembly attached.

[0011] Another exemplary embodiment of the present disclosure provides a mold handling manufacturing line comprising a first subline and a second subline. The mold handling manufacturing line moves at least one mold carriage supporting a casting mold for forming a casting part. The mold handling manufacturing line comprises at least a first subline and a second subline and a first conveying station. The second subline is arranged substantially parallel to and spaced apart from the first subline. The first conveying station communicates with the first subline and the second subline. The first conveying station includes a conveying cart configured to receive the at least one mold carriage. The first conveying station is positioned substantially centered relative to the first conveying station and includes a servobelt drive line comprising a servo motor that rotates one or more drive pulleys via a belt, the belt being coupled to the conveying cart. When the servo motor rotates in a first rotational direction, this causes the belt, positioned on the one or more drive pulleys, to move the conveying cart in a first linear direction between the first subline and the second subline. Furthermore, when the servo motor rotates in the second rotational direction, this causes the belt, positioned on the one or more drive pulleys, to move the transport cart in the second linear direction between the first subline and the second subline.

[0012] In the embodiments described above and other embodiments, the servo motor of the first transport station can rotate a ball screw, the ball screw can move a rod linearly, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hall bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this may cause the ball nut and the thrust tube to move linearly with the transport cart of the first transport station attached. Furthermore, the mold handling manufacturing line may further include an index actuator operating adjacent to the second transport station and the second sub-line, the index actuator may include a servo actuator that rotates to move a rod attached to an index block, the dog may be rotatable about a pivot pin on the index block, the dog may be biased in a first rotational direction, and a stopper may be engageable with the dog to restrict the dog's movement in the first rotational direction, the servo actuator may rotate to extend the index block when the first transport cart of the second transport station is positioned adjacent to the second sub-line, and the dog may be configured to engage with the at least one mold trolley to pull the at least one mold trolley from the transport cart of the second transport station onto the second sub-line.

[0013] Another exemplary embodiment of the present disclosure provides a mold handling manufacturing line comprising a first subline, a second subline, and a first conveying station. The second subline is arranged substantially parallel to and spaced apart from the first subline. The first conveying station communicates with the first and second sublines. The first conveying station also includes a conveying cart configured to receive the at least one mold trolley. As part of the first conveying station, a servo actuator moves a rod in a first linear direction and a second linear direction. The rod is attached to the conveying cart of the first conveying station, so that when the rod moves in the first linear direction and the second linear direction, the conveying cart of the first conveying station is movable in the first linear direction and the second linear direction. This moves the conveying cart of the first conveying station between the first subline and the second subline.

[0014] In the embodiments described above and other embodiments, the servo actuator of the first transport station can rotate a ball screw, the ball screw can move the rod linearly, the ball screw may include a thrust tube and a ball nut attached to the thrust tube, the ball nut may include one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw, and when the ball screw rotates, this may cause the ball nut and the thrust tube to move linearly with the transport cart of the first transport station attached. Furthermore, the mold handling manufacturing line may further include an index actuator operating adjacent to the second transport station and the second sub-line, the index actuator may include a servo actuator that rotates to move a rod attached to an index block, the dog may be rotatable about a pivot pin on the index block, the dog may be biased in a first rotational direction, and a stopper may be engageable with the dog to restrict the dog's movement in the first rotational direction, the servo actuator may rotate to extend the index block when the first transport cart of the second transport station is positioned adjacent to the second sub-line, and the dog may be configured to engage with the at least one mold trolley to pull the at least one mold trolley from the transport cart of the second transport station onto the second sub-line.

[0015] Additional features of mold handling systems will become apparent to those skilled in the art when considering exemplary embodiments of mold handling systems that are currently recognized.

[0016] The concepts described in this disclosure are shown by way of example in the accompanying drawings and are not limited thereto. For the sake of brevity and clarity of illustration, the elements shown in the drawings are not necessarily drawn to scale. For example, for clarity, the dimensions of some elements may be exaggerated relative to other elements. Further, reference numerals may be repeated between the drawings to indicate corresponding or similar elements where appropriate.

Brief Description of the Drawings

[0017] [Figure 1] FIG. 1 is a schematic view looking down on a mold or casting part manufacturing line.

[0018] [Figure 2] FIG. 2 is a side view showing a mold carriage with a mold placed thereon.

[0019] [Figure 3] FIG. 3 is another side view showing a mold carriage with a mold placed thereon.

[0020] [Figure 4] FIG. 4 is a perspective view showing a mold placed on a mold carriage.

[0021] [Figure 5] FIG. 5 is a perspective view showing a part of the drag portion and cope portion of a mold.

[0022] [Figure 6] FIG. 6 is an enlarged perspective view showing a part of the drag portion and cope portion.

[0023] [Figure 7] FIG. 7 is a side view showing a part of a prior art conveying station in a prior art manufacturing line.

[0024] [Figure 8]Figure 8 is a graph showing the relative virtual change in velocity with respect to position between a hydraulically driven actuator and a servo-driven actuator.

[0025] [Figure 9] Figure 9 is another schematic diagram showing a top-down view of the casting parts manufacturing line.

[0026] [Figure 10] Figure 10 is a detailed isolated perspective view of the jacket lift assembly of the mold station.

[0027] [Figure 11] Figure 11 is another detailed isolated perspective view of the jacket lift assembly of the mold station.

[0028] [Figure 12] Figure 12 is another detailed isolated perspective view of the jacket lift assembly of the mold station.

[0029] [Figure 13] Figure 13 is another detailed isolated perspective view of the jacket lift assembly of the mold station.

[0030] [Figure 14] Figure 14 is a separate perspective view of the transport station.

[0031] [Figure 15] Figure 15 is another separated perspective view of the transport station.

[0032] [Figure 16] Figure 16 is another isolated perspective view of the transport station.

[0033] [Figure 17] Figure 17 is another isolated perspective view of the transport station.

[0034] [Figure 18] Figure 18 is a lateral cross-sectional view of the index actuator system.

[0035] [Figure 19] Figure 19 is another separated lateral cross-sectional view of the index actuator system.

[0036] [Figure 20] Figure 20 is another separated lateral cross-sectional view of the index actuator system.

[0037] [Figure 21] Figure 21 is another separated lateral cross-sectional view of the index actuator system.

[0038] [Figure 22] Figure 22 is a detailed end view showing part of the index actuator and mold trolley.

[0039] [Figure 23] Figure 23 is a detailed perspective view showing a portion of a manufacturing line that includes multiple sub-lines.

[0040] [Figure 24] Figure 24 is another detailed perspective view showing a portion of the manufacturing line, which includes multiple sub-lines.

[0041] [Figure 25] Figure 25 is another detailed perspective view showing a portion of the manufacturing line, including multiple sub-lines.

[0042] [Figure 26] Figure 26 is another detailed perspective view showing a portion of the manufacturing line, including multiple sub-lines.

[0043] [Figure 27] Figure 27 is a detailed perspective view showing another conveying station and multiple sub-lines.

[0044] [Figure 28] Figure 28 is another detailed perspective view showing a different conveying station and multiple sub-lines.

[0045] [Figure 29] Figure 29 is another detailed perspective view showing a different conveying station and multiple sub-lines.

[0046] [Figure 30] Figure 30 is another detailed perspective view showing a different conveying station and multiple sub-lines.

[0047] [Figure 31] Figure 31 is a detailed perspective view of the sand push-off station.

[0048] [Figure 32] Figure 32 is another detailed perspective view of the sand push-off station.

[0049] [Figure 33] Figure 33 is another detailed perspective view of the sand push-off station.

[0050] [Figure 34] Figure 34 is another detailed perspective view of the sand push-off station.

[0051] [Figure 35] Figure 35 is another detailed perspective view of the sand push-off station.

[0052] [Figure 36] Figure 36 is another detailed perspective view of the sand push-off station. [Modes for carrying out the invention]

[0053] Corresponding reference numerals indicate corresponding parts across several drawings. The examples described herein illustrate embodiments of a mold handling system, and such examples should not be construed in any way as limiting the scope of such mold handling system.

[0054] The drawings and descriptions provided herein may be simplified to illustrate aspects (features) relevant to a clear understanding of the devices, systems, and methods described herein. For clarity, other aspects (features) that may be found in typical devices, systems, and methods have been omitted. Those skilled in the art will recognize that other elements and / or operations may be desirable and / or necessary to implement the devices, systems, and methods described herein. Such elements and operations are well known in the art and would not facilitate a better understanding of this disclosure, and therefore descriptions of such elements and operations may not be provided herein. However, this disclosure is deemed to essentially include all such elements, variations, and modifications to the described aspects (features) that would be known to those skilled in the art.

[0055] In one exemplary embodiment of the present disclosure, a hydraulic actuator is not required to move the mold carriage on the production line. Instead, a servo actuator is used, which can accelerate and decelerate more slowly than a hydraulic actuator. The use of a servo actuator provides more precise movement, enables smoother acceleration and deceleration, and reduces sudden starts and stops.

[0056] In a further exemplary embodiment, a servo motor may be coupled to a ball screw, pulley system, etc., for use as part of a transport station, to provide smoother acceleration and deceleration while moving a mold cart between multiple sublines. The transport cart may be mounted on a thrust tube that is linearly movable as a result of the rotation of the ball screw. When the servo motor rotates, it rotates the ball screw, which in turn moves the thrust tube linearly. In this design, a ball nut mounted on the thrust tube includes one or more concentric threads of a ball bearing that moves along the corresponding threads of the screw shaft. When the screw shaft rotates, it moves the ball nut, which in turn moves the thrust tube linearly back and forth. With the cart mounted on the thrust tube, when the servo motor rotates and thereby rotates the ball screw, there is a better ability for smoother acceleration and deceleration while moving the cart from one subline to the next, unlike the abrupt start and stop of a hydraulic actuator.

[0057] In another embodiment, the thrust tube may be mounted on a rotating dog which can be used to remove the mold cart from the transport cart and place it on a subline. The servo motor provides gradual acceleration and deceleration via the thrust tube, thereby resulting in a smoother movement when pulling the mold cart from the cart. In contrast, a hydraulic actuator instantly pulls the mold cart from the cart, generating abrupt movements that risk causing damage. Since this mold cart pushes and indexes (slides) adjacent mold carts, doing so more gently reduces the risk of damage to the mold and / or casting parts while sequentially indexing (sliding) segments. In a further embodiment, a pulley system may be mounted on the servo motor to move the cart between sublines.

[0058] The additional features and advantages of the mold handling line will become apparent to those skilled in the art, given the following detailed description of the currently recognized implementation of mold handling lines.

[0059] A schematic diagram of a mold or cast part manufacturing line 2, viewed from above, is shown in Figure 1. Manufacturing line 2 consists of four exemplary sublines 4, 6, 8, and 10. These sublines 4-10 may extend substantially parallel to one another. It is understood that manufacturing line 2 may consist of more or fewer sublines than shown here. Manufacturing line 2 is capable of manufacturing cast parts such as valves and couplings. These cast parts are formed from molten metal into the shape formed in the sand mold. The molten metal is then allowed to cool and solidify to form the part, which is then removed from manufacturing line 2.

[0060] In the illustrated embodiment, part molds (see Figures 2 to 7) are manufactured at a mold station 12 (see Figures 10 to 13). The molds are then placed on mold trolleys 16 located on one of a plurality of segments 14 that form each of the sublines 4 to 10. Here, when a part mold is manufactured, it is placed on a segment 14 of subline 10. Each segment 14 represents the space occupied by each mold trolley 16 on each of the sublines. Each "X" box shown in Figure 1 represents a single mold trolley 16 on one segment 14 of each subline, and is configured to move along the manufacturing line 2. Multiple mold trolleys 16 (e.g., more than 100) move along, for example, sublines 4, 6, 8, and 10 to manufacture cast parts. It is understood that the mold trolleys 16 are positioned adjacent to each other so as to push each other from one end to the other along the subline.

[0061] Each mold trolley 16 is also sized to accommodate a mold and a jacket surrounding the mold. Once the mold is formed (see Figures 2 to 7) and the jacket surrounds the mold on the mold trolley 16 (see Figures 10 to 13), the mold moves along the subline 10 in direction 18 to reach the transport station 22. Here, the mold trolley 16 is set on a transport cart 24 that moves the mold trolley 16 in direction 26. To transport the mold trolley 16 onto the subline 4, the mold trolley 16 is pulled out from the transport cart 24 in direction 20 and transported onto the subline 4. As shown in the figure, along the subline 4, the mold trolleys 16 are lined up in a full row adjacent to each other. When a mold cart 16 is moved or indexed (slid) onto subline 4, it then pushes the adjacent mold cart in direction 20, indexing (sliding) one segment 14 to it along subline 4. This triggers a chain reaction, causing each consecutively adjacent mold cart 16 to similarly index (slide) along subline 4 in direction 20. When this occurs, the mold cart 16 at the end of subline 4 is moved onto the transport cart 32 of transport station 30 and moved in direction 28 until it reaches subline 6. When this occurs, the mold cart 16 is moved onto subline 6 in direction 18, pushing or indexing (sliding) the adjacent mold cart 16 in direction 18. All consecutively adjacent mold carts similarly index (slide) one segment 14 in direction 18 on subline 6.

[0062] As shown in the figure, the transport station 30 may include not only a transport cart 32 but also a transport cart 34. As shown in the figure, when the transport cart 32 is moved in direction 26 to transport the mold cart 16 from subline 4 to subline 6, at the same time another mold cart 16 is placed on the transport cart 34 from subline 8 and moved in direction 28. This transports the latter mold cart 16 from subline 8 to subline 10. Those skilled in the art will understand, upon reading this disclosure, how moving or indexing (sliding) one mold cart 16 from one segment 14 to another segment 14 results in an organized chain reaction in which all the other carts move by one segment 14 along any of the sublines 4, 6, 8, or 10, or are placed on the transport carts and moved to the new sublines 4, 6, 8, or 10. This is a continuous process for the efficient manufacture of cast parts.

[0063] When a mold cart 16 is added to subline 6 and when a mold cart 16 is removed from subline 6, it continues to move in direction 18 along subline 6 because it is pushed by adjacent mold carts 16. In this case, when a mold cart 16 is indexed (slid) to the end of subline 6, it is placed on a transport cart 38 of transport station 36. The mold cart 16 is then moved from subline 6 to subline 8 in direction 28. When a mold cart 16 reaches subline 8, it is removed from the transport cart in direction 20 and indexed (slid) onto subline 8. As previously described for sublines 4 and 6, the continuous addition of mold carts 16 to subline 8 and the continuous removal of mold carts 16 from subline 8 causes each mold cart 16 to index (slide) one segment 14, until finally the mold cart 16 reaches the end of subline 8.

[0064] At the end of subline 8, when the mold cart 16 is indexed (slid) again, it is moved from subline 8 onto the transport cart 34 of transport station 30. At this point, the transport cart 34 moves in direction 28 to transport the mold cart 16 from subline 8 to subline 10. Then, as with the other sublines 4, 6, and 8, on subline 10 as well, the mold cart 16 moves in direction 18, pushing adjacent mold carts 16 to index (slide) one segment 14. This creates another chain reaction of each consecutive mold cart 16, with adjacent mold carts indexing (sliding) along subline 10 in direction 18. With respect to the transport station, it is understood that after the mold cart 16 is removed from the transport cart, the transport cart returns to its original position and becomes available to move the next mold cart 16 from one subline to another.

[0065] The purpose of moving all of these mold carriages continuously along sublines 4, 6, 8, and 10 is to allow the molten material inside the mold to solidify without disturbance within the mold. The process for mold carriage 16 ends when it reaches the sand push-off station 40 located adjacent to the mold station 12 (see Figures 31 to 36). At the sand push-off station 40, the jacket is lifted from mold carriage 16, and the sand and molded parts are pushed out of mold carriage 16. The parts are recovered, and the sand is recycled. The mold carriage 16 then continues to index (slide) in direction 18 along subline 10 until a new mold and jacket are placed at the mold station 12 and the entire process is restarted.

[0066] Figure 2 shows a side view of the mold trolley 16 with the mold 42 placed on it. This figure shows the drag 44 portion of the mold 42 placed on the surface 46 of the mold trolley 16. The shape of the molded structure, i.e., the part pattern 48, is formed in both the lower drag 44 portion and the upper cope 50 portion of the mold 42. To accommodate the molten material necessary to fill the part pattern, at least one sprue 52 and a runner 54 are formed in the cope 50 of the mold 42. The sprue 52 provides fluid communication from the outside of the cope 50 to the inside of the runner 54, and the runner 54 is in fluid communication with the part pattern 48. Thus, the molten material can be injected into the sprue 52 and then injected into the part pattern 48 along the runner 54. A parting line 56 defines the boundary between the drag 44 and the cope 50. In this exemplary embodiment, rollers 58 are also shown positioned at the bottom of the mold trolley 16 to allow movement of the mold trolley 16 along sublines 4, 6, 8, and 10.

[0067] The problem with the mold manufacturing line is that the molds tend to be shaken and damaged on the mold cart 16. Each of the drags 44 and copes 50 of the mold 42 is manufactured from sand pressed into the desired shape. This means that the mold 42 is inherently fragile (easily broken). There are opportunities (potential) for damage to occur during the movement of the aforementioned mold cart 16 between sublines 4, 6, 8, and 10, and along sublines 4, 6, 8, and 10. For example, when the mold cart 16 is transported from one subline to another, a hydraulic actuator (see Figure 7) typically moves the transport cart. Due to the nature of hydraulic actuators, acceleration and deceleration occur almost instantaneously (see Figure 8). When this (acceleration or deceleration) occurs, the drags 44 on the surface 46 of the mold cart 16 may stop slightly faster than the copes 50 on it. When this phenomenon occurs, a lateral shift may be generated between the drags 44 and the copes 50. This lateral shift is the relative displacement of the drag 44 to the cop 50 and can damage the image of the part pattern in the mold 42 or the molded part itself.

[0068] For this purpose, another side view of the mold trolley 16 with the mold 42 mounted on it is shown in Figure 3. Unlike the mold trolley 16 shown in Figure 2, where the mold 42 is on top, the mold 42 in Figure 3 is laterally shifted. The copes 50 are moving laterally relative to the drag 44, shifting these parts of the mold relative to each other at the parting line 56. This movement can distort the part pattern 48 formed within the mold 42. If this occurs before the molten material is injected, the resulting part may not be formed in the correct shape. If this lateral shift occurs after the material for the part has been injected, the shifting copes 50 may damage the cooling portion inside the mold 42. In either case, the consequences are detrimental. It is also recognized that the sudden starting and stopping of the hydraulic actuators can cause the mold trolleys 16 to collide with each other, resulting in damage to the mold 42. In other words, there is a substantial opportunity (possibility) during the manufacturing process for cast parts to be damaged during production.

[0069] Figure 4 shows a perspective view of the mold 42 resting on the mold trolley 16. A closer look at the image in Figure 4 reveals that the mold 42 shows exemplary damage 60 to the cope 50. This is because the mold trolley 16 was moved via hydraulic action. Figure 5 shows the cope 50 partially separated from the drag 44. The sprue 52 is shown extending into a part pattern 48 formed in the drag 44. Due to the sudden starting and stopping of the hydraulic action, a portion of the part pattern 48 is damaged, as indicated by reference numeral 62.

[0070] A magnified view of parts of the drag 44 and cop 50 in Figure 5 is shown in Figure 6. Here, the damage 62 to the part pattern 48 illustrates how the part pattern 48 can be easily damaged within the mold 42.

[0071] A side view of a portion of a transport station on a manufacturing line is shown in Figure 7 of the prior art. Here, with a piston arm 66 and a coupling 68 attached to a transport cart 32, a hydraulic actuator 64 moves the transport cart 32 between sublines in directions 28 and 26 (see, for example, Figure 1). At the end of the path movement, there is a stopper 74 to ensure that the transport cart 32 stops in the appropriate position relative to the subline. Due to the nature of the hydraulic actuator 64 and the stopper 74, there is an ongoing risk of damage occurring as a result of sudden starts and stops. As shown, after the mold 42 moves in direction 70 and is stopped by the stopper 74, the cop 50 may be moved against drag 44 along the parting line 56 (which may result in damage similar to that shown in Figures 3 to 6).

[0072] To illustrate the difference between hydraulic and servo-driven actuators, Graphs 72 and 73 in Figure 8 show the relative hypothetical changes in velocity 71 over position 75, comparing hydraulic and servo-driven actuators. A hydraulic actuator, as shown in Graph 72, accelerates almost instantaneously from zero to high speed, as indicated by line 76, the tube or rod on the actuator moves at a constant speed, as indicated by line 77, and then decelerates almost instantaneously, as indicated by line 78. In contrast, Graph 73 of a servo-driven actuator shows a gradual acceleration, as indicated by line 79. After this stepwise acceleration, the tube or rod moves at a constant speed 80, and then gradually decelerates (81). It should be noted that the lines and units on Graphs 72 and 73 are merely illustrative to illustrate the comparison between the operation of hydraulic and servo-driven actuators. These lines do not represent actuators actually tested side-by-side. Nevertheless, in contrast to abrupt increases and decreases in speed, gradual increases and decreases in speed reduce the risk of drag 44 and corp 50 shifting relative to each other while moving along production line 2.

[0073] Another schematic diagram overlooking the casting parts manufacturing line 2 is shown in Figure 9. Manufacturing line 2 consists of sublines 4, 6, 8, and 10, similar to that shown in Figure 1. A mold station 12, transport stations 22, 30, and 36, and a push-off station 40 are also shown. A jacket lift assembly 104 is used at mold station 12 to place the mold jacket 124 onto the mold 42 (see Figures 10 to 13). With respect to transport station 22, a transport cart 24 moves the mold trolley 16 between sublines 10 and 4 via a servo belt drive line 88. At the starting position of each subline 4, 6, 8, and 10, an index actuator 94 is positioned adjacent to the respective transport station to pull the mold trolley 16 from the transport cart onto the subline.

[0074] The transport station 30 includes a transport actuator 96 that moves two transport carts 32 and 34 between sub-line 4 and sub-line 6, and between sub-line 8 and sub-line 10. An index actuator 94 is also located adjacent to the transport station 30 and pulls the mold cart 16 onto sub-line 6 and 10, respectively. With respect to the transport station 36, it includes a transport actuator 98. Similar to the transport actuator 96, the transport actuator 98 moves the transport cart 38 between sub-line 6 and 8. Another index actuator 94, associated with sub-line 8 and located adjacent to the transport station 36, is configured to pull the mold cart 16 from the transport cart 38 onto sub-line 8. The push-off station 40 includes a push-off actuator 200 and another jacket lift actuator 202 (not shown in this figure; see Figures 31 to 36).

[0075] Detailed separated perspective views of the jacket lift assembly 104 of the mold station 12 are shown in Figures 10, 11, 12, and 13. These figures illustrate the process of placing the mold 42 onto the mold vehicle 16 on the subline 10. Figure 10 shows the mold station 12 including a lifter frame 106 supporting a jacket lift assembly 104 that is vertically movable in directions 110, 112. The jacket lift assembly 104 includes a frame 114 attached to a jacket lift arm 116. An electric servo actuator 118 having a retractable rod 120 that is movable in directions 110, 112 is attached to the base 122 of the lifter frame 106. The rod 120 is attached to the frame 114 to move the frame 114 in either direction 110, 112. Since the frame 114 is attached to the jacket lift arm 116, when the servo actuator 118 moves the rod 120 in direction 110, the jacket lift arm 116 moves upward in direction 110 relative to the subline 10. This is the position of the jacket lift arm 116 shown in Figure 10. Conversely, as shown in Figure 12, when the servo actuator 118 retracts the rod 120 and moves the frame 114 in direction 112 to lower the jacket, the lift arm 116 moves toward the subline 10. Figure 10 shows the formed mold 42 ready to be transported onto the mold trolley 16. This means that the lift arm 116, which holds the jacket 124 that fits over the mold 42 to protect the mold 42 as it moves along the production line 2, is suspended above the mold trolley 16.

[0076] A detailed separated perspective view of the jacket lift assembly 104 shown in Figure 11 includes a servo actuator 118 that maintains a rod 120 in an extended position to hold the frame 114 in a raised position above the mold trolley 16. The mold 42 is moved onto the mold trolley 16 in direction 26. When this occurs, as shown in Figure 12, the servo actuator 118 retracts the rod 120 in direction 112, lowering the jacket lift arm 116, which in turn lowers the jacket 124 onto the mold trolley 16 above the mold 42. Once the jacket 124 is placed on the mold trolley 16, the mold trolley 16 may be indexed (slid) by one segment and begin its movement through the production line 2.

[0077] The fingers 130 extend from the jacket lift arm 116 and hold the jacket 124 while lifting it, but allow the jacket 124 to be removed from the jacket lift arm 116 when moved in direction 18 along the subline 10. As shown in Figure 13, the mold trolley 16 with the jacket 124 on the mold 42 is indexed (slid) by one segment 14 in direction 18 from its original position shown in Figures 10, 11 and 12 (see Figures 1 and 9). When this occurs, the next mold trolley 16 shown in Figures 10, 11 and 12 is also indexed (slid) in direction 18 to a position to receive the new mold 42.

[0078] As further shown in Figure 13, the servo actuator 118 extends the rod 120 again. When the mold carriage 16 is indexed (slid) to the position shown here, the jacket 124 engages with the fingers 130 of the jacket lift arm 116. This holds the jacket 124 to such an extent that it can be lifted in direction 110 by the servo actuator 118 as shown. This allows the molding process to resume for this mold carriage 16, as shown in Figure 10. It is recognized that this process is repeated for each mold carriage 16 that is indexed (slid) by one segment 14 to the position shown in Figures 10 to 12. As also shown in Figure 13, another mold carriage 16 is waiting to receive another mold through this process.

[0079] The next step in the process of forming the cast parts is to transport the mold trolley 16, shown in Figures 10 to 13, to a new sub-line 4. On sub-line 4, the actual parts are cast. However, transporting the mold trolley 16 with the mold 42 on it carries the risk that the mold 42 may be damaged. This is because the mold trolley 16 is not only indexed (slid) segment by segment 14, but is also placed on a transport cart 24 at the transport station 22, and the transport station 22 moves the transport cart 24 to sub-line 4. This starting and stopping is the type of event that can damage the mold 42, as previously described with respect to Figures 2 to 8.

[0080] The process of transporting the mold cart 16 with the mold 42 and jacket 124 positioned on it is shown in the progress diagrams of Figures 14, 15, 16, and 17. It should be noted that in order to transport the mold cart 16 from sub-line 10 to sub-line 4, the mold cart 16 needs to move across the width of sub-lines 6 and 8. For the transport station 22, a servo belt drive line 88 provides relatively smooth starting and stopping of the mold cart 16. A servo motor 132 is centrally located as shown in the figure and rotates the drive pulleys 134, 136, 138, and 140 via a belt 142. As shown in the figure, when the servo motor 132 rotates, it causes the belt 142 positioned on the pulleys 134, 136, 138, and 140 to move the transport cart 24 in either direction 26 or direction 28. Pulleys 138 and 140 extend over the travel lengths in the directions 26 and 28 along which the transport cart 24 moves. For example, when the servo motor 132 rotates in the first direction, it moves the belt 142 in direction 26, thereby moving the transport cart 24 from subline 10 shown in Figure 14 to subline 4 shown in Figure 16. Conversely, when the mold trolley 16 is positioned adjacent to subline 4, rotating the servo motor 132 in the opposite direction moves the belt 142 in the opposite direction 28, returning the transport cart 24 to be adjacent to subline 10. These figures also show an exemplary rail 148 along which the transport cart 24 moves between sublines 4 and 10.

[0081] The perspective view of the transport station 22 shown in Figure 15 similarly includes a transport cart 24 positioned on rail 148 and a servo belt drive line 88 positioned below it. This figure differs from the figure shown in Figure 14 in that the mold carts 16 are indexed (slid) by one segment and placed on the transport cart 24. As previously mentioned, it is understood that multiple mold carts 16 are indexed (slid) by one segment 14 by an adjacent mold cart 16 pushing another adjacent mold cart 16 by the distance of one segment 14. This is typically achieved by pulling the mold carts off the transport cart and adding them to the subline. In the case of Figure 15, when the mold carts 16 are pulled off the transport station 30 onto the subline 10, all the mold carts 16 positioned on the subline 10 are indexed (slid) by one segment 14. When the last mold cart 16 is at the end of the subline 10, it is positioned on the transport cart 24, as shown in Figure 15, at the next moment when it is moved one segment by the loading of another mold cart 16 from the transport station 30.

[0082] The fact that the mold trolley 16 is positioned on the transport cart 24 and attached to the belt 142 means that when the servo motor 132 rotates, the belt 142 on the pulleys 134, 136, 138, and 140 moves in direction 26, thereby moving the mold trolley 16 toward sub-line 4. Because the motor speed and belt speed accelerate and decelerate gradually, this transport of the mold trolley 16 between sub-lines 10 and 4, shown in Figures 14 to 16, does not result in the sudden starts and stops similar to those of a hydraulic actuator (see graph 72 for the hydraulically driven actuator and graph 73 for the servo-driven actuator in the comparison in Figure 8). This reduces the risk of damage to the mold as shown in Figures 2 and 6. When the mold trolley 16 is removed from the transport cart 24, the servo motor 132 may rotate in the opposite direction, thereby moving the belt 142 toward the opposite direction 28, allowing the transport cart 24 to return to its starting position adjacent to sub-line 10.

[0083] When the transport cart 24 is moved to sub-line 4, the mold cart 16 is pulled out from the transport cart 24 in direction 26 via the index actuator 94 (see Figures 18 to 22). When the index actuator 94 pulls the mold cart 16 onto sub-line 4, the mold cart 16 pushes adjacent mold carts (not shown in this figure) by one segment 14. This creates a chain reaction, where each successive mold cart 16 similarly pushes and is pushed out (i.e., indexed / slid) by one segment 14. When the mold cart 16 is continuously indexed (slid) and reaches the end of sub-line 4, the mold cart 16 is moved to the transport station 30 (see Figures 23 to 26).

[0084] The continuous indexing (sliding) motion of the mold trolley 16, one segment at a time, is primarily achieved by the index actuators pulling the mold trolley 16 from the transport cart onto the sub-lines. As shown in the figure, the index actuators 94 are positioned at the starting end of each sub-line 4, 6, 8, and 10, as shown in Figure 9. It is understood that the operation of the index actuators 94 on each of the sub-lines 4, 6, 8, and 10 is substantially identical.

[0085] Each index actuator 94 is positioned below the subline, as shown in the figure, and is extendable outward from there. A rotating member or rotating dog is positioned near the end of the index actuator. The dog is rotatable in one direction but not fully rotatable in the other direction, and as the index actuator extends, the end of the dog can be moved below the transport cart. When the dog is moved below the transport cart, it is rotated so as not to obstruct it. When it reaches below the transport cart, the dog rotates back to an upright position to function as a hook. As the index actuator is pulled back in the opposite direction, the dog engages the mold cart with the transport cart and the index actuator pulls it until the mold cart is placed on the subline. At that point, as described above, the mold cart pushes an adjacent mold cart by one segment. The latter mold cart pushes yet another adjacent mold cart by one segment along the subline.

[0086] A detached lateral cross-sectional view of the index actuator 94, along with the mold trolley 16 mounted on the transport cart 24, is shown in the progress diagrams of Figures 18, 19, 20, and 21. It is understood that this arrangement can be used for any of sublines 2, 4, 6, and 10. Therefore, the transport cart 24 shown in these progress diagrams is illustrative. Furthermore, it is understood that other transport carts from other transport stations can be used in a similar manner to the transport cart 24 in these figures.

[0087] The separated lateral cross-sectional view in Figure 18 shows an index actuator 94, which includes a servo actuator 150 that moves the rod 152, similar to those previously described with respect to the servo actuators of this disclosure. A fixed bracket 154 connects the rod 152 to an index block 156. A dog 158 is rotatable in directions 162 and 164 about a pivot pin 160. It is understood that the dog 158 is spring-loaded to be biased in direction 164. Furthermore, it is understood that a stopper (not shown) may be associated with the dog 158 to stop movement in direction 164 when the dog 158 reaches a substantially upright position as shown in Figure 18. When a transport cart, such as a transport cart 24, transports the mold trolley 16 to a new sub-line, such as sub-line 4, the servo actuator 150 positions the rod 152 in a retracted position. With the transport cart 24 carrying the mold trolley 16 to the front of the sub-line 4, the mold trolley 16 is in a position to be pulled onto the sub-line 4 by the index actuator 94.

[0088] As shown in the separated lateral cross-sectional view of Figure 19, when the servo actuator 150 extends the rod 152, the rod 152 moves the index block 156 in direction 18. This causes the dog 158 to be pushed in direction 162 to counteract the biasing force when the dog 158 strikes the bottom corner 166 of the front panel 170 of the mold trolley 16. It is understood that the dog 158 may be configured to strike any part of the mold trolley 16. Furthermore, the transport cart 24, like other transport carts, may include a slot or cavity, such as a cavity 168, to receive a portion of the index block 156. As the servo actuator 150 continues to extend the rod 152 in direction 20, the dog 158 is pushed further down the mold trolley 16.

[0089] In the separated lateral cross-sectional view shown in Figure 20, the servo actuator 150 has completed the extension of the rod 152, the index block 156 has moved sufficiently downward, and the dog 158 has passed the corner 166 of the panel 170. When this occurs, the spring biasing force in direction 164 (see Figure 18) applied again to the dog 158 causes the dog 158 to rotate in direction 164. Next, with the aim of pulling the mold trolley 16 in direction 20, the servo actuator 150 pulls the rod 152 back in direction 20, causing the dog 158 to engage with the front panel 170.

[0090] As shown in the separated lateral cross-sectional view of Figure 21, the servo actuator 150 continues to move the rod 152 in direction 20, pulling the index block 156 that is pulling the mold trolley 16 via the dog 158, and removing the mold trolley 16 from the transport cart 24. Although not shown in this figure, when this occurs, the mold trolley 16 engages with an adjacent mold trolley 16 on the subline and indexes (slides) one segment. Also, as shown in Figure 19, the servo actuator 150 rotates the dog 158 around the pivot pin 160 so that it does not obstruct the mold trolley 16, by returning the rod 152 in direction 18, so that the mold trolley 16 can reset its position to engage with another mold trolley 16 that is being transported onto the transport cart 24 as it continues to move.

[0091] Detailed end views of at least a portion of the index actuator 94 and the mold trolley 16 are shown in Figure 22. In this figure, the servo actuator 150 is positioned below subline 4. An exemplary track 172 may be positioned on each side of the rail wall 174. The index block 156 may include a roller bearing 176 or other similar bearing structure to allow the index block 156 to move in directions 18 and 20. Part of the dog 158 is positioned behind the front panel 170 (see dashed line of the dog 158), which allows the mold trolley 16 to be pulled out from the transport cart 24 in direction 20. Rollers 178 may be coupled to the mold trolley 16 to assist in allowing the mold trolley 16 to move on the rail wall 174. It is understood that the same arrangement may be used in all of sublines 4, 6, 8, and 10.

[0092] The mold trolley 16 continues to index (slide) along subline 4 until it reaches its end. It is understood that while it is on subline 4, casting material may be poured into the mold 42. For the remainder of the time the mold trolley 16 moves along sublines 4, 6, 8, and 10, the casting material is allowed to cool until the mold trolley 16 is removed and the mold and sand are recycled at the sand push-off station 40 (see Figures 31 to 36).

[0093] A detailed perspective view of part of production line 2, including sublines 4, 6, 8, and 10, is shown in Figure 23. In this figure, the mold cart 16 is indexed at the end of subline 4 and positioned to be transported to another subline. Similar diagrams of production line 2 are also shown in Figures 24, 25, and 26. These are all progress diagrams showing how the mold cart 16 can be transported from subline 4 to subline 6, and from subline 8 to subline 10, respectively. The transport station 30 is configured to move two mold carts at a time from one subline to another.

[0094] As shown in Figure 23, a mold cart 16 on subline 4 is ready to be indexed (slid) onto a transport cart 32. Similarly, one mold cart 16 is positioned to be indexed (slid) onto a transport cart 34. The process of indexing the mold carts 16 from sublines 4 and 8 to transport carts 32 and 34, respectively, is performed simultaneously. Once this is done, the transport actuator 96 moves the transport carts 32 and 34 in direction 28, transporting the mold carts 16 to sublines 6 and 10, respectively. The transport carts 32 and 34 are connected to each other via a connector 179, and it is understood that both move simultaneously. The transport actuator 96 includes a servo actuator 180 that moves a rod 182 in either direction 26 or 28, as previously described with respect to other servo actuators. The rod 182 is attached to the transport cart 32, and when the rod 182 is moved in direction 26 or 28, the transport cart 34 also moves in the same direction. As a result of this arrangement, both transport carts 32 and 34 move simultaneously. This allows one servo actuator to move two mold carts between two separate mold lines. Since the acceleration and deceleration of the servo actuator 180 are gentler than those of a hydraulic actuator, it is understood that the risk of damage to the mold 42 during such a transport process is reduced.

[0095] Figure 24 shows each mold cart 16 indexed one segment in direction 20 and positioned on the respective transport carts 32, 34. As shown in Figure 25, the transport carts 32, 34 are moved in direction 28 by the servo actuator 180 retracting the rod 182, but provide a gentler transport process, as illustrated by the acceleration line 79 in the servo-driven actuator graph 73 in Figure 8. Next, as shown in Figures 18 to 21, the mold carts 16 can be pulled onto their respective sublines 6, 10 via the index actuator 94.

[0096] As shown in Figure 9, index actuators 94 are used at the starting ends of sublines 6 and 10, respectively. By pulling the mold carts 16 onto sublines 6 and 10, respectively, the transport carts 32 and 34 are released, and the servo actuator 180 of the transport actuator 96 can move the rod 182 in direction 26, allowing the mold carts 32 and 34 to return to their original positions and await placement on them for transport.

[0097] The mold cart 16 is indexed (slid) along subline 6 one segment at a time. This allows the molten material in the mold 42 to cool and solidify during this time. At the end of subline 6, the mold cart 16 needs to be transported to subline 8 (see also Figure 9). A transport station 36, equipped with a transport cart 38 and a transport actuator 98, moves the mold cart 16 from subline 6 to subline 8.

[0098] In the detailed perspective view of Figure 27, the mold cart 16 is positioned at the end of subline 6 and is ready to be indexed (slid) onto the transport cart 38. The process of moving the mold cart 16 from subline 6 to subline 8 is shown in the detailed perspective views of Figures 27, 28, 29, and 30. For example, the detailed perspective view of Figure 28 shows the mold cart 16 being indexed (slid) one segment 14 in direction 18 to reach the transport cart 38. Once this is done, the mold cart 16 moves along track 188 in direction 28 and proceeds to subline 8. The servo actuator 190 retracts rod 192 (see also Figures 29 and 30) to pull the transport cart 38 to subline 8. Here again, the transport actuator 98 operates as described above, providing smoother transport of the mold cart 16 between sublines 6 and 8 according to the acceleration line 79 of the servo-driven actuator graph 73 in Figure 8. Therefore, despite being moved between sublines, there is no sudden starting or stopping of the hydraulic actuator, thus reducing the risk of damage to the mold 42 (see also Figure 7).

[0099] Next, using the process described above in Figures 18 to 21, the mold carriage 16 can be indexed (i.e., pulled) onto the subline 8 via another index actuator 94 (see also Figure 9). Then, the servo actuator 190 of the transport actuator 96 can extend the rod 192 to return the transport cart 38 to the subline 6 in direction 26, allowing another mold carriage to await. Furthermore, it is understood that the mold carriage 16 on the subline 8 is indexed segment by segment along the subline 8, allowing the molten material in the mold 42 to cool during this process. When the mold carriage 16 reaches the end of the subline 8 as shown in Figure 23, the mold carriage 16 can be indexed (slid) onto the transport cart 34 as shown in Figure 24, and can move to the subline 10 as shown in the progress diagrams of Figures 23, 24, 25, and 26. After the index actuator 94 pulls the mold trolley 16 onto the subline 10 (see also Figure 9), the molten material continues to solidify within the mold 42.

[0100] As shown in Figure 9, the end of the line for the mold trolley 16 is at the sand push-off station 40, details of which are shown in Figures 31, 32, 33, 34, 35, and 36. In these figures, the jacket 124 is removed from the mold 42 and pushed off (extruded) onto the shake-out conveyor 234 along with the casting parts (the mold 42). The casting parts are then separated from the sand, and the sand is recycled into another mold. The jacket 124 is returned to the mold trolley 16 and indexed (slid) along the sub-line 10 to prepare the new mold 42 for positioning, as shown in Figures 10 to 13, and the process resumes.

[0101] Figure 31 shows a sand push-off station 40 with a jacket lift assembly 204. The jacket lift assembly 204 includes a jacket lift actuator assembly 208 that holds a jacket lift actuator 202. The jacket lift actuator 202 raises and lowers a mounted jacket lift arm 116 via a frame 214. The lift frame assembly 204 includes a rolling lifter frame 206 mounted on rolling brackets 220 located on both sides of the lower lifter frame 206. Rollers 222 on the rolling brackets 220 move along rails 223, allowing the lower lifter frame 206 to move in directions 28, 26. A push-off actuator 200, including a servo actuator 224 and a rod 226, selectively extends and retracts the lower lifter frame 206 in directions 28, 26. This movement allows a push panel 228 to move above the mold trolley 16 to push the mold 42 out of the mold trolley 16, as shown in the subsequent progress diagram.

[0102] As shown in Figure 32, the jacket 124 on the mold trolley 16 fits between the jacket lift arms 116. When in this position, as shown in Figure 33, the servo actuator 230 of the jacket lift actuator 202 extends the rod 232, lifting the frame 214 in direction 110, as described herein, and lifts the jacket 124 away from the mold trolley 16 and the mold 42.

[0103] With the mold 42 exposed, the servo actuator 224 of the push-off servo actuator 200 extends the rod 226 in direction 28, as shown in Figure 34. This causes the roller 222 to roll along the rail 223 and the roller lifter frame 206 to move in direction 28. This causes the push panel 228 to move above the mold trolley 16, pushing the mold 42 off the mold trolley 16 and sending it to the shakeout conveyor 234, where the parts are removed and the sand is recycled. Once the mold 42 is removed, the push-off servo actuator 200 further extends the lower lifter frame 206 in direction 28, with the jacket 124 still held by the jacket lift arm 116. The jacket lift actuator 202 retracts the rod 232, thereby lowering the frame 214 in direction 112, so that the jacket 124 fits above the jacket brush 236, as shown in Figure 35. The jacket brush 236 is understood to be used to clean the inside of the jacket 124 before accepting a new mold.

[0104] Figure 36 shows the roller lifter frame 206 being retracted by the push-off servo actuator 200 pulling the rod 226 in direction 26, returning the lower lifter frame 206 to its original position. This returns the jacket 124 to above the mold trolley 16. It can then move in direction 18 by indexing (sliding) one segment, and the process at the mold station 12 as shown in Figure 10 can be repeated.

[0105] In drawings, certain structural or methodological features may be shown in a specific arrangement and / or order. However, it is understood that such a specific arrangement and / or order may not be required. Rather, in some embodiments, such features may be arranged in a different manner and / or order than those shown in the illustrative drawings. Furthermore, the inclusion of structural or methodological features in certain drawings does not mean that such features are essential in all embodiments, and in some embodiments they may not be included or may be combined with other features. Also, it is understood that if the subject matter disclosed in this non-provisional patent application conflicts with that of the priority application, the disclosure in this non-provisional patent application shall prevail.

Claims

1. A mold handling manufacturing line for moving at least one mold trolley that supports a casting die for forming a cast part, The first sub-line and A second subline is arranged substantially parallel to and spaced apart from the first subline, A third subline is arranged substantially parallel to and spaced apart from the first subline and the second subline, A fourth subline is arranged substantially parallel to and spaced apart from the first subline, the second subline, and the third subline, A first transport station communicating with the fourth subline and the first subline, Equipped with, The first transport station includes a transport cart configured to receive at least one mold trolley, The first transport station is positioned approximately in the center of the first transport station and includes a servo belt drive line composed of servo motors that rotate one or more drive pulleys via a belt. The belt is connected to the transport cart, When the servo motor rotates in the first rotational direction, this causes the belt positioned on the one or more drive pulleys to move the transport cart in the first linear direction between the fourth subline and the first subline. When the servo motor rotates in the second rotational direction, this causes the belt positioned on the one or more drive pulleys to move the transport cart in the second linear direction between the fourth subline and the first subline. The second transport station is located distal to the first transport station. The second transport station is in communication with the first subline, the second subline, the third subline and the fourth subline, The second transport station includes a first transport cart configured to receive at least one mold trolley, and a second transport cart configured to receive at least one other mold trolley. As part of the second transport station, a servo actuator moves the rod in the first linear direction and the second linear direction. The rod is attached to the first transport cart of the second transport station and the second transport cart of the second transport station. As a result, when the rod moves in the first and second linear directions, causing the first transport cart of the second transport station to move between the first and second sub-lines, and the second transport cart of the second transport station to move between the third and fourth sub-lines, both the first transport cart of the second transport station and the second transport cart of the second transport station are movable in the first and second linear directions. A mold handling manufacturing line characterized by the following features.

2. The one or more drive pulleys of the first transport station include a first pulley and a second pulley, The first pulley is spaced a certain distance from the second pulley, and this distance is at least the travel length of the first transport cart. The mold handling manufacturing line according to feature 1.

3. When the servo motor rotates in the first rotational direction, this causes the belt positioned on the one or more drive pulleys to move the transport cart in the first linear direction to the fourth sub-line. When the servo motor rotates in the second rotational direction, this causes the belt, positioned on the one or more drive pulleys, to move the transport cart in the second linear direction to the first sub-line. The mold handling manufacturing line according to feature 1.

4. Index actuators operating adjacent to the first transport station and the first sub-line Furthermore, The index actuator includes a servo actuator that rotates to move a rod attached to the index block, The dog is rotatable around the pivot pin on the index block, The aforementioned dog is biased in the first rotational direction, The stopper is engageable with the dog so as to restrict the movement of the dog in the first rotational direction, When the transport cart of the first transport station is positioned adjacent to the first subline, the servo actuator rotates to extend the index block. The dock is configured to engage with the at least one mold trolley and pull the at least one mold trolley from the transport cart of the first transport station onto the first subline. The mold handling manufacturing line according to feature 1.

5. Index actuators operating adjacent to the second transport station and the second sub-line Furthermore, The index actuator includes a servo actuator that rotates to move a rod attached to the index block, The dog is rotatable around the pivot pin on the index block, The aforementioned dog is biased in the first rotational direction, The stopper is engageable with the dog so as to restrict the movement of the dog in the first rotational direction, When the first transport cart of the second transport station is positioned adjacent to the second sub-line, the servo actuator rotates to extend the index block. The dock is configured to engage with the at least one mold trolley and pull the at least one mold trolley from the transport cart of the second transport station onto the first subline. The mold handling manufacturing line according to feature 1.

6. Index actuators operating adjacent to the second transport station and the fourth subline Furthermore, The index actuator includes a servo actuator that rotates to move a rod attached to the index block, The dog is rotatable around the pivot pin on the index block, The aforementioned dog is biased in the first rotational direction, The stopper is engageable with the dog so as to restrict the movement of the dog in the first rotational direction, When the second transport cart of the second transport station is positioned adjacent to the fourth sub-line, the servo actuator rotates to extend the index block. The dock is configured to engage with another at least one mold trolley to pull the other at least one mold trolley from the transport cart of the second transport station onto the fourth subline. The mold handling manufacturing line according to feature 1.

7. The servo actuator of the second transport station rotates a ball screw, and the ball screw moves the rod in a straight line. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly while the first transport cart of the second transport station and the second transport cart of the second transport station are attached. The mold handling manufacturing line according to feature 1.

8. The servo actuator of the index actuator rotates a ball screw, and the ball screw moves the rod in a straight line. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly with the index block attached. The mold handling manufacturing line according to feature 6.

9. A third transport station located distal to the second transport station. Furthermore, The third transport station is in communication with the second subline and the third subline. The third transport station includes a transport cart configured to receive at least one mold trolley, As part of the third transport station, a servo actuator moves the rod in the first linear direction and the second linear direction. The rod is attached to the transport cart of the third transport station, so that when the rod moves in the first and second linear directions to move the transport cart of the third transport station between the second and third sub-lines, the transport cart of the third transport station is movable in the first and second linear directions. The mold handling manufacturing line according to feature 6.

10. The servo actuator of the third transport station rotates a ball screw, and the ball screw moves the rod in a straight line. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly when the transport cart of the third transport station is attached. The mold handling manufacturing line according to feature 9.

11. A jacket lift assembly configured to place a mold jacket above the mold on at least one of the mold trolleys. Furthermore, The jacket lift assembly includes one or more jacket lift arms, The servo actuator includes a frame-mounted extendable rod attached to one or more jacket lift arms, which is attached to the one or more jacket lift arms to extend or retract the jacket lift arms. The mold handling manufacturing line according to feature 1.

12. The servo actuator of the jacket lift assembly rotates a ball screw, which moves the rod linearly. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly while the frame of the jacket lift assembly is attached. The mold handling manufacturing line according to feature 11.

13. A sand push-off station configured to remove the casting mold made of sand from at least one of the mold trolleys. Furthermore, The sand push-off station includes a jacket lift actuator assembly and a push-off actuator assembly, The jacket lift actuator assembly includes a jacket lift servo actuator configured to selectively raise and lower one or more jacket lift arms via a frame in order to remove the jacket before removing the sand from the casting mold on at least one mold trolley, The push-off actuator assembly includes a push-off servo actuator having an extendable rod for moving the jacket lift actuator assembly. After the jacket lift actuator assembly has lifted the jacket from the mold, the push-off servo actuator is configured to move the jacket lift actuator assembly and the mold seated on the at least one mold trolley. The mold handling manufacturing line according to feature 1.

14. The push-off servo actuator of the push-off actuator assembly rotates a ball screw, which moves the rod linearly. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly while the frame of the push-off actuator assembly is attached. The mold handling manufacturing line according to feature 13.

15. A mold handling manufacturing line for moving at least one mold trolley that supports a casting die for forming a cast part, At least the first subline and the second subline, A first transport station communicating with the first subline and the second subline, Equipped with, The second subline is arranged substantially parallel to and spaced apart from the first subline. The first transport station includes a transport cart configured to receive the at least one mold trolley, The first transport station is positioned approximately in the center of the first transport station and includes a servo belt drive line composed of servo motors that rotate one or more drive pulleys via a belt. The belt is connected to the transport cart, When the servo motor rotates in the first rotational direction, this causes the belt positioned on the one or more drive pulleys to move the transport cart in the first linear direction between the first subline and the second subline. When the servo motor rotates in the second rotational direction, this causes the belt, positioned on the one or more drive pulleys, to move the transport cart in the second linear direction between the first subline and the second subline. A mold handling manufacturing line characterized by the following features.

16. The servo motor of the first transport station rotates a ball screw, and the ball screw moves the rod in a straight line. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly while the transport cart of the first transport station is attached. The mold handling manufacturing line according to feature 15.

17. Index actuators operating adjacent to the second transport station and the second sub-line Furthermore, The index actuator includes a servo actuator that rotates to move a rod attached to the index block, The dog is rotatable around the pivot pin on the index block, The aforementioned dog is biased in the first rotational direction, The stopper is engageable with the dog so as to restrict the movement of the dog in the first rotational direction, When the first transport cart of the second transport station is positioned adjacent to the second sub-line, the servo actuator rotates to extend the index block. The dock is configured to engage with the at least one mold trolley and pull the at least one mold trolley from the transport cart of the second transport station onto the second subline. The mold handling manufacturing line according to feature 15.

18. A mold handling manufacturing line for moving at least one mold trolley that supports a casting die for forming a cast part, At least the first subline and the second subline, A first transport station communicating with the first subline and the second subline, Equipped with, The second subline is arranged substantially parallel to and spaced apart from the first subline. The first transport station includes a transport cart configured to receive at least one mold trolley, As part of the first transport station, a servo actuator moves the rod in a first linear direction and a second linear direction. The rod is attached to the transport cart of the first transport station, and as a result, when the rod moves in the first linear direction and the second linear direction, causing the transport cart of the first transport station to move between the first sub-line and the second sub-line, the transport cart of the first transport station is movable in the first linear direction and the second linear direction. A mold handling manufacturing line characterized by the following features.

19. The servo actuator of the first transport station rotates a ball screw, and the ball screw moves the rod in a straight line. The ball screw includes a thrust tube and a ball nut attached to the thrust tube, The ball nut includes one or more concentric threaded portions of a hole bearing that move along the corresponding threaded portion of the ball screw. When the ball screw rotates, this causes the ball nut and the thrust tube to move linearly while the transport cart of the first transport station is attached. The mold handling manufacturing line according to feature 18.

20. Index actuators operating adjacent to the second transport station and the second sub-line Furthermore, The index actuator includes a servo actuator that rotates to move a rod attached to the index block, The dog is rotatable around the pivot pin on the index block, The aforementioned dog is biased in the first rotational direction, The stopper is engageable with the dog so as to restrict the movement of the dog in the first rotational direction, When the first transport cart of the second transport station is positioned adjacent to the second sub-line, the servo actuator rotates to extend the index block. The dock is configured to engage with the at least one mold trolley and pull the at least one mold trolley from the transport cart of the second transport station onto the second subline. The mold handling manufacturing line according to feature 18.

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