Walking Beam Conveyor for Sand Mold Lateral Transfer
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Solution Overview
Problem
There is a need for an improved conveyor system to efficiently transport sand molds from a mold forming device to a metal pouring station, particularly for machines not originally designed to work together, while ensuring mold integrity and flexibility in handling vertical height differences and lateral entry onto the conveyor.
Innovation Solution
The solution involves a walking beam-type accumulating conveyor with a transfer rail system that includes adjustable outboard and central rails, a pusher mechanism for lateral transfer, and a mold lift platform to manage vertical height differences and facilitate side entry onto the conveyor, allowing for continuous and flexible mold conveyance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a linear conveyor connects mold forming devices to carousel conveyors, then mold transport is achieved, but the system lacks flexibility when machines are not originally designed to work together and cannot handle vertical height differences or lateral entry
Solution Approach 1:
The conveyor system employs a walking beam mechanism where the beam moves in a reciprocating motion, allowing dynamic adaptation to different machine configurations. The beam can be positioned at various angles and heights, enabling lateral entry and vertical height difference accommodation without requiring complete system redesign.
Solution Approach 2:
The walking beam conveyor is designed to perform multiple functions: it can handle lateral entry from different directions, accommodate various vertical height differences, and connect different types of molding machines to carousel conveyors. This multi-functional design eliminates the need for machine-specific conveyor configurations.
2Reliability
If traditional conveyor systems are used, then mold transport is achieved, but mold integrity may be compromised due to rigid handling and inability to accommodate lateral entry
Solution Approach 1:
The walking beam provides gentle, dynamic mold handling by moving the entire beam with the mold rather than rigidly transferring it at fixed points. This reduces shock and impact forces on the mold, maintaining integrity while accommodating lateral entry positions.
Solution Approach 2:
The walking beam acts as an intermediary between the lateral entry point and the carousel conveyor. It absorbs and translates the lateral motion into forward progression, protecting the mold from direct impact forces while enabling lateral entry operation.
3Productivity
If one sand mold forming machine is offline, then maintenance or replacement is needed, but continuous operation cannot be maintained with traditional conveyor systems
Solution Approach 1:
The walking beam conveyor maintains continuous mold flow from multiple molding machines to the carousel conveyor. When one machine is offline, the beam continues to transport molds from other machines without interruption, ensuring continuous operation of the casting process.
Solution Approach 2:
The conveyor system is designed to accept molds from multiple independent molding machines simultaneously. This multi-source capability allows the system to compensate for machine downtime by redirecting mold flow from operational machines, maintaining overall productivity.
4Adaptability or versatility
If fixed rail conveyors are used, then simple structure is achieved, but installation flexibility between different machine stations is limited
Solution Approach 1:
The rail system transitions from fixed to adjustable positioning. The walking beam rails can be positioned at different locations and angles to accommodate various machine station configurations, providing installation flexibility while maintaining structural integrity through controlled adjustability rather than complete flexibility.
Data Source
AI summary
Method and apparatus for feeding sand molds laterally and/o between stations of differing heights. The method and apparatus of this invention utilize walking-beam-type conveyors having spaced apart fixed outboard rails and a central reciprocating rail. Walking-beam conveyors can be disposed in perpendicular directions with a junction therebetween that allows for a perpendicular change in direction. The method and apparatus of this invention include lift, leveling, and/or lateral transfer mechanisms for lateral placement of the stations relative to the conveyance path.