Replaceable Crown Pouring Nozzle for Casting Furnaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing casting nozzles suffer from wear-induced changes in flow dynamics, leading to casting defects and requiring frequent replacement, which is costly and time-consuming.
Innovation Solution
Designing the casting nozzle in two parts, with a removable and replaceable crown that can be easily positioned and secured using assembly paste and a bandage system, allowing for local material property adaptation and efficient replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the pouring nozzle is designed as a single integrated component, then the structural integrity and simplicity are improved, but the replacement time and cost increase significantly when wear occurs
Solution Approach 1:
The pouring nozzle is divided into two separate components: a base body that remains in the casting furnace and a crown that can be removed and replaced. The guide channel is formed by the combination of both parts, with the crown containing the exit area that is subject to wear. This segmentation allows the crown to be replaced independently without replacing the entire nozzle, significantly reducing replacement time and cost while maintaining the functional integrity of the complete nozzle assembly.
2Loss of time
If the crown is made replaceable and separate from the base body, then replacement cost and time are reduced, but the positioning precision and secure mounting become more difficult
Solution Approach 1:
The crown and base body feature asymmetric geometric shapes that complement each other. The crown has a specific non-symmetric form that fits into the base body in only one correct orientation, ensuring precise positioning and proper alignment of the guide channel. This asymmetric design prevents incorrect installation while maintaining ease of replacement.
Solution Approach 2:
The crown is designed to be inserted into and nested within the base body structure. The crown fits into a receptacle or socket formed in the base body, creating a nested arrangement where the smaller crown component is housed within the larger base body. This nesting arrangement ensures secure mounting while allowing straightforward insertion and removal for replacement purposes.
3Adaptability or versatility
If different materials are used for the base body and crown, then local adaptation to load zones is improved, but the manufacturing complexity increases
Solution Approach 1:
Different materials are selected for the crown and base body based on their specific functional requirements and exposure to different conditions. The crown, which is exposed to direct molten metal contact and high wear at the exit area, can be made from a material with superior wear resistance or thermal properties. The base body, which experiences different thermal and mechanical conditions, can be made from a material optimized for those conditions. This local quality approach allows each component to be manufactured from the most suitable material for its specific service conditions.
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
This design minimizes downtime and costs by allowing quick replacement of the crown, maintaining flow dynamics and preventing casting defects, while enabling adaptation to different load zones and applications.
Implementation Method 1
The assembly paste can preferably be thermally decomposable, so that the crown can be detached from the crown base again after the casting process and can be replaced if necessary.
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a pouring nozzle (22) for guiding a melt out of an outlet (12) of a casting furnace (2) in a moulding box (16) by means of a guiding channel (36), said pouring nozzle comprising a base body (24) and a crown (32) placed on the base body (24), the guiding channel (36) being guided through both the base body and the crown, the base body (24) comprising a connecting piece (26) with a front side that can be inserted into the outlet (12) and into which the guiding channel (36) enters, a flange (28) for applying to the casting furnace (2), which connects to the connecting piece (26) on a side opposing the front side, and a crown base (30) for carrying the crown (32), embodied on the flange (28), opposite the connecting piece (26).