Automatic Pouring Method for High-Speed Molding Lines
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Solution Overview
Problem
Stopper-type pouring machines in high-speed molding lines face issues with molten metal leakage due to impurities and abrasion, and ladle-tilting-type machines struggle to maintain high-speed pouring required for these lines.
Innovation Solution
An automatic pouring method using a ladle-tilting-type machine with a holding furnace and pouring hopper that tilts forwardly to supply molten metal, allowing for continuous pouring by measuring weight and adjusting flow volume, ensuring consistent high-speed pouring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a stopper-type pouring machine is used for high-speed pouring, then pouring speed is improved, but reliability deteriorates due to molten metal leakage from stopper adhesion to impurities and abrasion
Solution Approach 1:
The invention removes the stopper component entirely from the pouring system. By using a ladle-tilting mechanism instead of a stopper to control molten metal flow, the source of leakage problems (stopper adhesion to impurities and abrasion) is eliminated while maintaining high-speed pouring capability
Solution Approach 2:
Instead of controlling the flow by opening/closing a stopper within the pouring nozzle, the invention inverts the control mechanism by tilting the entire ladle to control the flow. The ladle tilts forward to pour and then tilts backward to stop pouring, completely avoiding the stopper-related reliability issues
2Reliability
If a ladle-tilting-type pouring machine is used to avoid stopper maintenance, then reliability is improved, but pouring speed deteriorates and cannot adapt to high-speed molding lines
Solution Approach 1:
The invention employs dynamic control of the ladle tilting mechanism with programmable speed and position control. The ladle can be tilted forward and backward at controlled speeds, and the pouring rate can be adjusted by controlling the tilting speed, enabling adaptation to high-speed molding lines while maintaining reliability
Solution Approach 2:
The invention changes the operational parameters of the ladle tilting mechanism, including tilting speed, angle, and acceleration profiles. By optimizing these parameters, the system achieves both high pouring speed and high reliability without the limitations of conventional ladle-tilting machines
3Duration of action of stationary object
If the pouring hopper is tilted forwardly to supply molten metal during pouring, then continuous pouring is achieved, but device complexity increases due to coordination between holding furnace and pouring hopper
Solution Approach 1:
The invention pre-fills the pouring hopper with molten metal before the actual pouring process. The holding furnace supplies molten metal to the pouring hopper in advance, ensuring that the hopper has sufficient metal储备 to complete the pouring cycle without interruption, thereby achieving continuous pouring
Solution Approach 2:
The invention uses weight sensors to monitor the molten metal level in the pouring hopper in real-time. When the weight drops below a predetermined threshold, the system automatically triggers the holding furnace to supply more molten metal, creating a closed-loop feedback control system that maintains continuous pouring operation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-speed pouring in high-speed molding lines by maintaining consistent molten metal flow and reducing maintenance costs associated with stopper-type machines.
Implementation Method 1
a holding furnace for storing and holding the molten metal therein and for supplying the stored molten metal by forwardly tilting the holding furnace
Implementation Method 2
forwardly tilting the pouring hopper and for pouring the molten metal into a mold therefrom
Implementation Method 3
if the weight of the molten metal within the pouring hopper has not reached a predetermined weight
Data Source
Figure 1
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AI summary
Provided is an automatic pouring method whereby even a tilting automatic pouring device can pour at high speed, accommodating high-speed molding on a high-speed molding line. Said method includes: a process wherein a pouring tank, which can hold an amount of molten metal sufficient for multiple pours, is tilted forward, thereby pouring the molten metal from inside said tank into a casting mold; a process wherein the pouring tank is tilted backward, thereby halting the aforementioned pouring into the casting mold; and a process wherein a set of casting molds, including the casting mold for which the aforementioned pouring had completed, are moved at intervals. During the period from the beginning of the process in which molten metal is poured into the casting mold to the end of the process in which the set of casting molds is moved at intervals, whenever the weight of molten metal in the pouring tank is less than a prescribed weight, molten metal is continually supplied to the pouring tank by tilting a holding furnace forward.