EP1501647B1 - Method and device for the weight-controlled filling of ingot molds in non-iron casting machines - Google Patents

Abstract

The invention relates to a method for the weight-accurate filling of ingot molds in a non-iron casting machine, e.g. a copper anode casting machine or a zinc anode casting machine, which is configured in the form of casting wheels that are use for production in a fully mechanized casting operation and are provided with the ingot molds. The aim of the invention is to obtain the desired precise-weight quality of a piece and exact plane parallelism of the bordering surfaces thereof. Said aim is achieved by carrying out the following steps: first, a liquid metal is introduced into an intermediate trough ( 4, 4 ') at a regulated mass flow rate, the continuous dynamic weight increase being simultaneously determined; second, liquid metal is fed into a dosing trough ( 4, 4 ') which is located on each side of the intermediate trough ( 4, 4 ') by alternately tilting the intermediate trough ( 4, 4 ') on one side followed by the other. After filling the first dosing trough ( 5 ), the intermediate trough ( 4 ) is tilted in the direction of the second dosing trough ( 5 ') while the mass of an anode is cast from the first filled dosing trough into one of the ingot molds ( 10, 10 ') that are arranged on the casting wheel ( 9, 9 ') by means of a controlled tilting movement. Also disclosed is a device for carrying out the inventive method.

Description

The invention relates to a method for accurate weight filling of molds of a non-iron casting machine, for example. A copper anode casting machine or zinc anode casting machine, which are designed for production in fully mechanical casting operation as casting wheels and equipped with the molds, wherein in a first step, liquid metal in a controlled mass flow under determination of the continuously dynamic weight gain introduced into a trough and fed in a second step by tilting the intermediate trough liquid metal alternately to one side in each existing Dosiermulde and after filling the first Dosiermulde the intermediate trough in Direction of the second Dosiermulde tilted and at the same time the mass of an anode from the first filled Dosiermulde is shed by a controlled tilting movement in one of the casting wheel arranged on the molds.

The invention also relates to a device for carrying out the method.

In contrast to the production of individual castings, for example, those in relatively small numbers of sand molds, anodes are produced from non-ferrous metals with relatively high quantities in fully mechanical casting operation using multiple molds made of cast iron, copper or steel. Characteristic features of the aspired quality of the anodes are considered to be the exact piece weight as well as the exact pianplexity of their surfaces.

Constant compliance with these parameters is achieved particularly advantageously in the use of pouring machines equipped with casting wheels. In this case, in the peripheral region, for example, one or two casting molds equipped with molds are provided in a tiltable arrangement, which are alternately filled with cast metal under continuous molds and then dumped into a respective mold at their standstill.

The known production method finds its natural limits with the difference in speed between the standing casting troughs and the casting troughs under the casting mold. The speed difference enforces the maximum attainable output of anode casting by unit weight, quantity and piece quality, in particular depending on the required service life of the casting wheel and the movement times including the times for accelerations and decelerations.

This calculates the cycle time, d. H. the period between the positioning of, for example, two molds, from the service life of the casting wheel for the purpose of filling, inspection and removal, and the. Movement times, acceleration or deceleration, whereby a superimposition of the movement times and the filling takes place.

From the document DE 1 956 076 A1 a method and a system for producing a higher number of copper anode plates is known. For this purpose, casting wheels are used, the molds are successively filled at a peripheral point with molten copper and then further rotated by a Gießformabstand. At shorter intervals metered quantities of melt are alternately entered from a single sampling point in at least two casting wheels, so that the one casting wheel is further rotated as long as the Abgießvorgang runs on the other casting.

For accurate casting of copper anode plates in the respective molds of a casting wheel is known from German Patent Application 2 011 698, that target weight of the anode plates prior to entering the casting metal into a mold, regardless of the actual weight of a cast previously anode plate by weighing a to determine the absolutely adjustable subset of a total of two to three times the subset amount.

The document JP 55 08 42 68 describes a method for increasing the efficiency of a casting machine with a casting wheel by using 2 pouring points. In the casting machine is under a spout an intermediate trough, which is provided with transverse outlets to their horizontal. Tilted axis. Dosing troughs for weighing the metal are arranged under each outlet and tiltable about the axis. Under the spout of Dosiermulden a mold is arranged in each case.

Document DE 1 956 076 A1 discloses a method and apparatus for producing a higher number of copper anode plates. For this purpose, metered quantities of melt are dispensed alternately from a single removal point into at least two casting wheels at short intervals, so that one casting wheel is further rotated as long as the casting process is carried out at the other or at another.
In this case, the inflow to the dosage is controlled by weighing the dosage underlying the total amount and the existing amount of melt, from which the subset is to be separated, is kept constant.

Based on the above-described prior art, the present invention seeks to provide an improved operating method and an improved design for non-iron casting machines in order to increase the product quality and to achieve a weight-accurate Kokillenbefüllung.

The aforementioned object is achieved by a method referred to in the preamble of claim 1, characterized in that the mass flow during casting is divided into preferably three phases.

• Anodengewichte
• unterschiedliche Ausgangsmengen von Schmelze in einer Dosiermulde
• Geometrie der Dosiermulde

In a first phase, the liquid metal is first poured into a mold with a relatively low mass flow, thereby avoiding splashes or spilling over. In a subsequent phase, after reaching a predetermined intermediate weight, a uniform filling of the molds 10, 10 'takes place with a higher mass flow. After a predeterminable metal cast weight has been reached again in a final phase, a final weight-accurate fine filling in the third phase takes place last. For this purpose, the tear-off point of the metal flow is chosen so that the predetermined weight tolerance is maintained. Relevant parameters for this are:

• anode weights
• different starting amounts of melt in a Dosiermulde
• Geometry of the dosing trough

In this case, in the casting machine for carrying out these casting operations, the pouring edge of the dosing trough is designed such that the kinetic energy of the pouring stream is reduced as far as possible during tipping and the melt enters the die as vertically as possible, as shown in FIG.

The casting machine for carrying out casting operations for the production of anodes of non-ferrous metal, such as copper or zinc anodes, according to the preamble of claim 6 is characterized in that at the front outlet of each Dosiermirlde a pouring edge is provided with step-shaped design.

With the aid of the operating method according to the invention, a fully mechanical casting operation can be ensured with comparatively high quantities using molds made of cast iron, copper or steel which can be reused many times, the cast anodes obtaining an exact piece weight and keeping the parallelism of their boundary surfaces as accurate as possible, ie those characteristics which characterize the desired quality of the cast anodes.

An embodiment of the method provides that alternately only one Dosiermulde is filled from the intermediate trough, while, with the other Dosiermulde the exact weight Feinbefüllung a mold

In triangular-shaped arrangement of Dosiermulden on a casting wheel takes place after filling both Dosiermulden the positioning of the next two empty dies.

In Y-shaped arranged Dosiermulden on two casting wheels takes place after completion of the filling of a Dosiermulde the positioning of the next empty mold under each currently filled Dosiermulde.

A particularly advantageous development of the invention is that the period between the positioning of two molds from service life of a casting wheel and movement times for positive or negative acceleration, for example, for filling, inspection or removal, calculated as so-called cycle time, with a superposition of the movement times and in particular the Filling is considered. As a result, in particular an overflow of the melt over the tolerances of the rocking or Schwappränder the molds is avoided and it can be guaranteed plane-parallel anode surfaces.

Further embodiments of the method according to the invention are provided according to the subclaims.

In a further inventive embodiment of the casting machine is proposed that means such as hydraulic cylinder for tilting each intermediate recess about its longitudinal axis and means, such as hydraulic cylinders for tilting each Dosiermulde provided about its transverse axis, and that means, for. B. load cells for the current detection of the weight content of the intermediate recesses and means, for. B. load cells are provided for the current detection of the weight content of Dosiermulden.

In the following the invention is shown in schematic drawings of a preferred embodiment, wherein from the drawings further advantageous details of the invention are removable.

Fig. 1

in Draufsicht die Eingießvorrichtung einer Metall-Gießmaschine mit zwei Gießrädern in V-förmiger Anordnung der Dosiermulden;

Fig. 2

die Eingießvorrichtung mit einem Gießrad bei einer Delta-förmigen Anordnung von einem Paar Dosiermulden, ebenfalls in Draufsicht;

Fig. 3

eine Dosiermulde in Rückansicht;

Fg. 4

die Dosiermulde in Horizontalposition einer Seitenansicht;

Fig. 5

die Seitenansicht einer Dosiermulde in Entleerungs-Kippposition;

Fig. 6

eine vergrößerte Schnittdarstellung vom vorderen Ausguss einer Dosiermulde;

Fig. 7

eine Seitenansicht einer Zwischenmulde mit Schwenklagerung;

Fig. 8

die Zwischenmulde mit Schwenklagerung und Schwenkantrieb in Rückansicht;

Fig. 9

eine perspektivische Darstellung der Eingießvorrichtung.

Show it:

Fig. 1

in plan view, the pouring device of a metal casting machine with two casting wheels in a V-shaped arrangement of Dosiermulden;

Fig. 2

the pouring device with a casting wheel in a delta-shaped arrangement of a pair of Dosiermulden, also in plan view;

Fig. 3

a Dosiermulde in rear view;

Fig. 4

the Dosiermulde in horizontal position of a side view;

Fig. 5

the side view of a Dosiermulde in emptying tilt position;

Fig. 6

an enlarged sectional view of the front spout of a Dosiermulde;

Fig. 7

a side view of an intermediate trough with pivotal mounting;

Fig. 8

the intermediate recess with swivel bearing and swivel drive in rear view;

Fig. 9

a perspective view of the pouring device.

The plan view of Fig. 1 shows the essential functional elements of a metal casting machine 9, 9 'in functional V-connection of Dosiermulden 5, 5' with an intermediate trough 4. This is by means of a tilting bearing axis xx tilted on both sides and empties it Molten metal through the outlets 6, 6 'in the Dosiermulden 5, 5'. As a means for tilting preferably position adjustable hydraulic cylinders 12, 12 'are arranged on one side of a Dosiermulde. The intermediate recess 4 is pivotally mounted at two points on a frame 16 about its longitudinal axis x-x, wherein the third attachment point is a hydraulic cylinder 11 is used. The frame 16 is also mounted on load cells 13 at at least three points. The load cells are arranged within the overall system so that no lateral forces act on the load cells and thus no incorrect measurements occur.

The Dosiermulden 5, 5 'are tiltably mounted by means of their transverse axes y-y from the horizontal position to a discharge position tilted forward. After tilting the intermediate recess in the longitudinal axis x-x, melt is filled into the associated dosing trough 5, 5 'after one side in each case via one of the outlets 6, 6' (FIGS. 3 and 5)

Weight-controlled melt is discharged from these dosing troughs into a respective mold 10, 10 'which is rotatably provided on the periphery of each casting wheel 9, 9'. In this case, an amount of liquid metal with exact weight by tilting the intermediate trough 4, 4 'alternately abandoned in each case one side by means of the lifting cylinder 11. At the same time an anode is off the first filled Dosiermulde 5, 5 'by the described controlled tilting movement in one of the casting edge 9,9' arranged molds 10, 10 'potted.

In alternation, in each case one dosing trough 5, 5 'is filled from the intermediate trough 4, while by means of the other dosing trough the exact weighting of the first mold 10, 10' takes place.

Here, the positioning of the next empty dies 10 takes place only after the previous filling of the two Dosiermulden 10, 10 ', and on the other hand the positioning of the next mold is carried out under the currently filled dosing trough.

For positioning, it should be noted that given the positive and negative acceleration states of the casting wheel 9, 9 ', the rocking edges of the anodes are kept within acceptable tolerances, and the production of plane-parallel anode surfaces is ensured.

The cycle times between the positioning of two molds are calculated from the service life of the casting wheel 9, 9 ', e.g. for filling, inspection and removal and the movement times such as positive or negative acceleration, with a superimposition of the movement times and the times for the filling takes place.

In addition to the above description remains nachzutragen that above the actual Eingießvorrichtung 1, an arbitrarily formed container 3 'is provided for molten metal 3, the one bundle of the same bundled beam of liquid metal in a feed trough 20 escape, the intermediate trough 4, 4' filled as Fig. 3 shows. A current weight control is carried out by storage of the or the support frame (s) 15 or 15 and 16 on the three load cells 13. Fig. 4 shows a mounted on the pivot bearing y-y and with the tilt cylinder 12 in tilt tendency gem. Fig. 5 adjustable Dosiermulde 5, 5 'with a front spout 7 in an enlarged view acc. Fig. 6. Fig. 7 and Fig. 8 show from different viewing directions, the seitenkippbare intermediate trough 4, 4 ', wherein the same components are used for the drawings with the same reference numerals.

• a) eine Menge flüssigen Metalls wird mit vorbestimmbarem Gewicht aus einem Anodenofen in eine Zwischenmulde 4, 4' einer Eingießvorrichtung geleitet, wobei der Massenstrom des flüssigen Metalls über die einstellbare Öffnung einer Ofenklappe geregelt wird. Als Regelgröße dient dabei das kontinuierlich ermittelte Gewicht der dynamisch zunehmenden Masse der Schmelze in die Zwischenmulde 4, 4'.
• b) durch Kippen der Zwischenmulde 4, 4' um ihre Längsachse, abwechselnd nach beiden Seiten mittels z.B. der Kippzylinder 11 wird flüssiges Metall jeweils in ein Paar Dosiermulden 5, 5' eingeleitet, wobei nach Befüllen der ersten Dosiermulde 5 nach Gewichtsprogramm die Zwischenmulde 4' in Richtung der zweiten Dosiermulde 5' gekippt und das vorgegebene Gewicht einer zu gießenden Anode in die Dosiermulde 5' vergossen wird, wobei durch Wägemittel 13 die Masse des flüssigen Metalls in der Zwischenmulde 4' ebenso wie in den Dosiermulden streng kontrolliert und damit die Befüllung der Mulden geregelt wird.

In the following, the operating method for the casting machine described above will be explained. It comprises the following process steps:

• a) an amount of liquid metal is made with predeterminable weight from an anode furnace in an intermediate trough 4, 4 'of a pouring device directed, wherein the mass flow of the liquid metal is regulated via the adjustable opening of a furnace flap. The controlled variable used here is the continuously determined weight of the dynamically increasing mass of the melt in the intermediate trough 4, 4 '.
• b) by tilting the intermediate trough 4, 4 'about its longitudinal axis, alternately to both sides by means of, for example, the tilting cylinder 11 liquid metal is in each case introduced into a pair Dosiermulden 5, 5', wherein after filling the first Dosiermulde 5 by weight program the intermediate trough 4 ' tilted in the direction of the second Dosiermulde 5 'and the predetermined weight of an anode to be cast in the Dosiermulde 5' is poured, wherein by weighing 13, the mass of the liquid metal in the intermediate trough 4 'as well as in the Dosiermulden strictly controlled and thus the filling of Mulden is regulated.

The emptying of Dosiermulden 5, 5 'in each case a mold 10 of the casting wheel 9 by lifting the rear portion of a Dosiermulde 5 by hydraulic cylinders 12, 12' means (not shown) position control. The troughs 5, 5 'are tilted over the axes y-y in an emptying inclined position.

Phase 1)

flüssiges Metall wird zunächst relativ langsam, d.h. mit geringem Massenstrom in jeweils eine Kokille 10 vergossen. Dadurch wird bei kurzzeitiger Durchsatzreduzierung Spritzen bzw. Überschwappen des Metalls vermieden, sowie Auswaschungen an den Kokillen unter Standzeitverlängerung reduziert.

Phase 2)

nach Erreichen eines vorgegebenen Gewichts von flüssigem Metall in eine zuordenbare Kokille 10 erfolgt nunmehr ein gleichmäßiges Befüllen mit einem höheren Massestrom.

Phase 3)

nach erneutem Erreichen eines vorbestimmten Gewichts an flüssigem Metall in der zuordenbaren Kokille 10 erfolgt eine gewichtsexakte Rest-Feinbefüllung der zugeordneten Kokille 10.

Hierfür wird der Abreißpunkt der Schmelzenströmung so gewählt, dass die Gewichtstoleranz eingehalten wird. Abhängige Verfahrensparameter hierfür sind:

• Anodengewichte
• unterschiedliche Ausgangsmengen von Schmelze in einer Dosiermulde 5
• Geometrie der Dosiermulde
• dabei ist die Ausgießkante 8, 8' der Dosiermulde 5, 5' so gestaltet, dass die kinetische Energie beim Kippvorgang reduziert wird und die Schmelze möglichst senkrecht in die Kokille einfließt.

The filling process of the mold from a Dosiermulde is carried out in three phases:

Phase 1)

Liquid metal is first relatively slowly, ie shed with a low mass flow in each case a mold 10. As a result, in the case of a short-term reduction in throughput, spraying or spilling over of the metal is avoided, and leaching from the molds is reduced while the service life is extended.

Phase 2)

after reaching a predetermined weight of liquid metal in a attributable mold 10 is now a uniform filling with a higher mass flow.

Phase 3)

after re-reaching a predetermined weight of liquid metal in the assignable mold 10 is a weight exact residual fine filling of the associated mold 10th

For this purpose, the tear-off point of the melt flow is chosen so that the weight tolerance is maintained. Dependent process parameters for this are:

• anode weights
• different starting amounts of melt in a Dosiermulde 5
• Geometry of the dosing trough
• In this case, the pouring edge 8, 8 'of the Dosiermulde 5, 5' designed so that the kinetic energy is reduced during tilting and the melt flows as perpendicular as possible in the mold.

In the interplay is now a Dosiermulde 5 or 5 'from the intermediate trough 4, 4' filled, while with the other Dosiermulde 5 'the exact weight fine filling of a mold.

LIST OF REFERENCE NUMBERS

1.

casting device

Third

Container / metal melt

4th

intermediate trough

5th

metering trough

6th

outlet

7th

front outlet

8th.

discharge edges

9th

casting wheels

10th

molds

11th

Means for tilting the intermediate trough

12th

Means for tilting the dosing troughs

13th

Means of weighing content intermediate troughs

14th

Means for weighing Contents dosing troughs

15th

Support frame lower part

16th

Support frame shell

17th

frame

18th

pivot bearing

19th

bearing supports

20th

feed channel

Claims (7)

1. A method for the weight-controlled filling of ingot moulds in a non-iron casting machine, for example, a copper anode casting machine or a zinc anode casting machine that comprises at least one casting wheel and is equipped with ingot moulds in order to realize a fully mechanized casting operation, wherein
   liquid metal is introduced into an intermediate trough (4, 4') at a regulated mass flow rate in a first step and the continuous dynamic weight increase is simultaneously determined, wherein liquid metal is alternately introduced into respective metering troughs (5, 5') located to both sides of the intermediate trough (4) in a second step by tilting the intermediate trough accordingly, and wherein the intermediate trough (4) is tilted, after filling the first metering trough (5), in the direction of the second metering trough (5') while the mass of an anode is simultaneously poured from the initially filled metering trough into an ingot mould (10, 10') arranged on the casting wheel (9, 9') by tilting the metering trough in a controlled fashion,
   characterized in
   that the mass flow rate during the casting process is divided into three phases, wherein the material being cast is initially poured into an ingot mould with a relatively slow mass flow rate in a first phase, wherein the ingot mould (10) is uniformly filled with a relatively high mass flow rate after a predetermined metal mass or metal weight is reached, and wherein the ingot mould is precision-filled in a weight-controlled fashion with a reduced mass flow rate in a third phase after another predetermined weight of the molten metal is reached.
2. The method according to Claim 1,
   characterized in
   that the intermediate trough (4) alternately fills only one respective metering trough (5) while an ingot mould (10) is precision-filled in a weight-controlled fashion by other metering trough (5').
3. The method according to Claim 1 or 2,
   characterized in
   that the positioning of the next two empty ingot moulds (10, 10') does not take place until both metering troughs are filled if the metering troughs (5, 5') are arranged on one casting wheel (9, 9') in a triangular fashion.
4. The method according to at least one of Claims 1-3,
   characterized in
   that the positioning of the next empty ingot moulds (10, 10') underneath the respective metering trough (5) currently being filled already takes place during the filling of the metering trough (5) if the metering troughs (5, 5') are arranged on two casting wheels (9, 9') in a Y-shaped fashion.
5. The method according to one of Claims 1-4,
   characterized in
   that the time period between the positioning of two ingot moulds (10, 10') is calculated in the form of the so-called cycle time from the standstill times of a casting wheel (9, 9') and the times in motion required for positive or negative accelerations, e.g., filling, inspection or removal, wherein a superposition of the times in motion and, in particular, the filling process is taken into account.
6. A casting machine for carrying out casting processes according to preceding Claims 1-5, particularly for manufacturing anodes of non-iron metals, e.g., copper or zinc anodes, wherein at least one intermediate trough (4, 4') with laterally directed outlets (6, 6') is provided underneath the spout of a melting furnace in order to receive a limited quantity of molten metal (3), wherein said intermediate trough is arranged stationarily and can be tilted about a horizontal longitudinal axis (x-x), wherein one respective metering trough that can be tilted about a lateral axis (y-y) is arranged underneath each outlet (6, 6') and spaced apart therefrom by a vertical projection, and wherein one respective ingot mould (10, 10') that consists of cast iron, copper or steel and is mounted on a casting wheel (9, 9') is respectively arranged underneath each pouring edge (8, 8') of a metering trough (5, 5') and spaced apart therefrom by a vertical projection,
   characterized in
   that a pouring edge (8, 8') of stepped design is provided on the front outlet (7, 7') of each metering trough (5).
7. The casting machine according to Claim 6,
   characterized in
   that means are provided for tilting each intermediate trough (4, 4') about its longitudinal axis (x-x), e.g., hydraulic cylinders (11, 11'), in that means are provided for tilting each metering trough (5, 5') about its lateral axis (y-y), for example, hydraulic cylinders (12, 12'), in that means are provided for actively determining the weight of the contents of the intermediate troughs (4, 4'), e.g., load cells (13, 13' and 13''), and in that means are provided for actively determining the weight of the contents of the metering troughs (5, 5'), e.g., load cells (14, 14' and 14'').

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