Methods and system for manufacturing castings utilizing an automated flexible manufacturing system

Abstract

A method and system for generating a production sequence for the control of resources and production for metal castings of a manufacturing plant. The system employs a transport system to transfer the castings between a series of processing stations, which could include heat treatment, quenching, decoring, demolding, cleaning, machining, inspection, storage, etc., served by the transport system. A series of guided vehicles moving along the transport carry the castings between the processing stations. Each guided vehicle includes an identifier monitored by a controller to direct the castings to the next required processing station according to a predetermined production sequence for the castings thereon.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present patent application is a formalization of previously filed, co-pending U.S. provisional patent application Ser. No. 60 / 813,938, filed Jun. 15, 2006. This patent application claims the benefit of the filing date of the cited provisional patent application according to the statutes and rules governing provisional patent applications, particularly 35 USC § 119(e)(1) and 37 CFR §§ 1.78(a)(4) and (a)(5). The specification and drawings of the provisional patent application are specifically incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] Traditionally, in conventional processes for forming metal castings, a mold, such as a metal die or sand mold having an interior chamber with the exterior features of a desired casting defined therein, is filled with a molten metal. A sand core that defines interior features of the castings is received and / or positioned within the mold to form the interior detail of the casting a...

AI Technical Summary

Benefits of technology

[0007] Briefly described, the present invention generally relates to a casting processing system for enabling the pouring, forming, heat treating, cleaning, aging, quenching, and further processing of castings formed from metal and / or metal alloys at enhanced rates and efficiency, and with greater flexibility and control of movement of the castings between various processing stations, as compared with conventional casting processes in which castings are processed in batches along a substantially uniform path through heat treatment, quenching, etc. The castings are formed at a pouring station at which a molten metal such as aluminum, iron, or a metal alloy, is poured into a mold or die, such as a permanent metal mold, semi-permanent mold, or a sand mold. A transfer mechanism then typically will transfer the castings to a series of guided vehicles, each generally including a series of racks and / or baskets defining compartments in which the castings are received for transport into and through a heat treatment station and / or other processing stations, according to a pre-programmed processing sequence or schedule for each casting or set of castings on the guided vehicles. During this transition from the pouring station to one or more downstream processing stations, the molten metal of the castings generally is permitted to cool to an extent sufficient to form the castings.

Problems solved by technology

However, during the transfer of the castings from the pouring station to the heat treatment station, and especially if the castings are allowed to sit for any appreciable amount of time, the castings may be exposed to the ambient environment of the foundry or metal processing facility.

As a result, the castings tend to rapidly cool down from a molten or semi-molten temperature.

This results in greater utilization of energy and, therefore, greater heat treatment costs.

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