Tilting Pouring Ladle Control for High-Speed Molten Metal Flow

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Solution Overview

Problem

Conventional tilting-type automatic pouring equipment for molten metal cannot achieve high-speed pouring, and stopper-type equipment faces issues with impurities and maintenance costs due to wear and bleeder problems.

Innovation Solution

The development of tilting-type pouring equipment that includes a holding furnace, a pouring ladle, a weight measurement device, and control equipment to manage tilting movements, allowing for precise control of molten metal flow based on calculated flow rates and specific product patterns, ensuring high-speed pouring without bleeder issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If stopper-type pouring equipment is used to enable high-speed pouring, then pouring speed is improved, but reliability deteriorates due to impurity adhesion and bleeder occurrences from stopper wear

Engineering Contradiction:

Improvepouring speedVSAvoidpouring quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The invention extracts and removes the stopper component from the pouring system, replacing it with a tilting ladle mechanism. This eliminates the source of impurity adhesion and bleeder occurrences while maintaining high-speed pouring capability through controlled tilting motion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the mechanical stopper opening/closing system with a tilting ladle mechanism. The pouring action is achieved through gravitational flow control via tilting angle adjustment rather than mechanical valve operation, thereby eliminating wear-related reliability issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If stopper-type pouring equipment is used to achieve high-speed pouring, then pouring speed is improved, but loss of time increases due to maintenance and replacement requirements

Engineering Contradiction:

Improvepouring speedVSAvoidmaintenance time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The tilting ladle mechanism uses simple, durable components that do not require frequent maintenance or replacement. The ladle and tilting mechanism are designed for long service life without the wear issues inherent in stopper-type systems, eliminating maintenance downtime.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If conventional tilting-type pouring equipment is used to avoid stopper wear problems, then reliability is improved, but productivity deteriorates due to inability to pour at high speed

Engineering Contradiction:

Improvepouring qualityVSAvoidpouring speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention introduces dynamic control of the tilting ladle through variable tilting speed and angle adjustment. By controlling the tilting motion dynamics, the system achieves both high pouring speed and reliable pouring quality, overcoming the limitations of conventional static tilting mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the operational parameters of the tilting mechanism by precisely controlling tilting angle, tilting speed, and tilting acceleration. These parameter adjustments enable the system to achieve high-speed pouring while maintaining pouring quality, resolving the contradiction between reliability and productivity.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If conventional tilting method is used to avoid stopper wear, then reliability is improved, but pouring precision deteriorates due to inability to control flow pattern

Engineering Contradiction:

Improveequipment durabilityVSAvoidpouring flow control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention incorporates feedback control by monitoring the actual pouring flow and adjusting the tilting ladle parameters in real-time. This ensures precise flow pattern control while maintaining the reliability advantages of the tilting mechanism, achieving both durability and pouring precision.

Inventive Principle:

Principle #23Feedback

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 of molten metal corresponding to molding speed, preventing bleeder occurrences and reducing maintenance costs by accurately controlling the tilting movements and flow rates, thus maintaining equipment efficiency.

Implementation Method 1

a device for measuring weight, which device measures the weight of the molten metal in the pouring ladle

Methodology Applied

Scientific EffectWeight measurement:

Data Source

PatentUS9289824B2Pouring equipment and method of pouring using the pouring equipment

Publication Date: 2016.03.22 SINTOKOGIO LTD

AI summary

The present invention provides pouring equipment of a tilting-type that can appropriately pour molten metal at a high speed corresponding to the speed of molding. It also provides a method of pouring the molten metal. The pouring equipment has a holding furnace supplying the molten metal by being tilted, a pouring ladle pouring the molten metal supplied from the holding furnace into molds that are intermittently transported, a device for measuring weight of the molten metal in the pouring ladle, and equipment for control that controls the tiltings of the holding furnace and the pouring ladle. The equipment for control has a device for storing results from measurements and devices for calculating the first and second flow rate. The equipment controls the tilting of the ladle so that the ladle pours the molten metal into the mold according to the flow pattern of the product.