Ladle Tilt Control via Molten Metal Surface Area
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Solution Overview
Problem
Existing pouring apparatuses, such as fan-shaped ladles, face challenges in maintaining molten metal temperature and controlling flow rates, leading to quality issues in cast products and higher manufacturing costs compared to cylindrical ladles.
Innovation Solution
A pouring apparatus with a cylindrical or conical ladle body and integrated nozzle, controlled by a tilt mechanism that adjusts the ladle's angle based on the surface area of molten metal to maintain a predetermined pouring position, allowing for precise control of flow rates and patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fan-shaped ladle is used, then the flow rate of pouring can be easily controlled, but the temperature of the molten metal decreases due to larger contact area with air
Solution Approach 1:
The invention changes the shape parameter of the ladle from fan-shaped to cylindrical or conical with specific curvature radius relationships. By setting the curvature radius of the side face portion to be 0.05 to 0.2 times the diameter of the top face, the surface area is minimized while maintaining pourability, thus reducing heat loss to air while preserving flow rate control capability
2Extent of automation
If a fan-shaped ladle is used, then pouring automation is achieved, but the manufacturing cost increases
Solution Approach 1:
The invention changes the ladle shape parameters from complex fan-shaped geometry to simpler cylindrical or conical forms with specific radius-to-diameter ratios. This parameter optimization maintains the automated pouring function while using standard, easier-to-manufacture shapes that reduce production costs
Solution Approach 2:
The cylindrical or conical ladle design with integrated nozzle serves multiple functions: it maintains molten metal temperature, enables automated pouring through tilt control, and provides cost-effective manufacturing. The universal design replaces the specialized fan-shaped ladle that required complex fabrication
3Ease of manufacture
If a cylindrical ladle is used, then manufacturing cost is reduced, but flow rate control becomes difficult
Solution Approach 1:
The invention optimizes the cylindrical or conical ladle parameters by setting the curvature radius of the side face portion to 0.05 to 0.2 times the diameter of the top face. This specific parameter range creates optimal hydrodynamic conditions that enable flow rate control comparable to fan-shaped ladles, while maintaining the manufacturing advantages of cylindrical/conical forms
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 accurate and automated pouring with improved temperature control and reduced manufacturing costs, ensuring consistent quality and efficiency in casting processes.
Implementation Method 1
a flow rate of pouring of molten metal can be easily controlled because a surface area of a top face of molten metal in the fan-shaped ladle is constant regardless of a tilt angle to enable pouring of molten metal at a flow rate in proportion to tilt angular speed
Data Source
AI summary
A pouring apparatus comprises a ladle configured to include a body and a nozzle, and a controller configured to control a tilt angle of the ladle, wherein the body includes a side face portion, an inner surface of the side face portion is formed in a cylindrical shape or in a conical shape, the nozzle includes a nozzle tip for guiding molten metal to the outside and is integrated with the body on a side of the body, in order to guide the molten metal in the body to the nozzle tip and to pour out the molten metal through the nozzle tip, and the controller controls the tilt angle on the basis of a surface area of the molten metal when the ladle is tilted.