RU2840555C2 - Molten metal casting mould comprising connection mechanism for protective casing, casting apparatus for pouring molten metal and method for pouring molten metal - Google Patents

Abstract

FIELD: foundry production.

SUBSTANCE: casting mould for molten metals comprises cavity (3) with inlet hole (4), housing (6), which outlet hole is connected with hole (4), and inlet hole is with channel (7) between mould surface (8) and inlet hole. Protective casing (9) including funnel fitted on hollow shaft end is fitted in channel (7) in pouring position. Mould and protective casing connection mechanism (14) comprises a base element fixed on mould surface (8), a mounting element receiving a funnel, and at least one collapsible element comprising one or more elastic elements, including a spring passing between the base element and installation element. Elements are connected to allow separation of mounting element from base element and movement of said elements when load is applied and deformation of at least one flexible element.

EFFECT: providing formation of sealing contact of funnel and pouring ladle nozzle during casting and reducing wear caused by friction between movable elements.

13 cl, 17 dwg

Description

AREA OF TECHNOLOGY

[001] The present invention relates to a mold comprising a mold/protective cover connection mechanism for a protective cover of a casting machine. It also relates to a mold assembly and a casting machine for pouring molten metal comprising a mold/protective cover connection mechanism, as well as to a method for pouring molten metals. The mold/protective cover connection mechanism of the present invention makes it possible to automatically and smoothly form a sealing contact between a ladle pouring nozzle and a protective cover without the intervention of a human operator or a robot.

LEVEL OF TECHNOLOGY

[002] One of the main problems in metal casting processes is to prevent air entrainment during casting. This can lead to the formation of defects, including air bubbles and oxide films, which lead to the formation of cracks in the casting. It is known from the prior art that in order to prevent air entrainment, the molten metal is poured using a protective casing, which reduces the re-oxidation of the metal during its pouring between the ladle and the mold. As shown in Fig. 6, the protective casing (10) is, for example, a hollow elongated shaft having a funnel at its proximal end (= inlet opening) and inserted into the mold channel with its distal end (= outlet opening), communicating with the gating system of the mold, for example, located under the casting cavity. A critical step in connecting the ladle pouring nozzle (12) to the inlet of the protective jacket at the funnel level is to form a sealing contact between the two and to maintain the sealing contact throughout the pouring operation.

[003] A system for pouring molten metals is disclosed in European patent application EP 3463715 B1. This system comprises:

• a mold comprising a casting cavity having an inlet opening and a channel extending between the upper surface of the mold and the inlet opening,

• a protective casing containing a funnel and a hollow shaft, wherein the funnel is located outside the mold near the upper surface, and the hollow shaft is placed in the channel and is designed to move in it.

[004] In order to form a sealing contact between the pouring nozzle and the funnel of the protective casing, EP 3463715 B1 proposes a lifting mechanism located on the upper surface of the mould. The lifting mechanism comprises concentrically arranged first and second bushings, wherein the first bushing is fixed on the upper surface of the mould, and the second bushing is rotatably connected to the upper surface of the mould and supports the funnel of the protective casing. A bayonet system comprising a pusher engaged with an inclined slot makes it possible to lift the second bushing relative to the upper surface of the mould by rotation, thus causing a linear movement of the protective casing. The rotation of the bayonet system is carried out by an operator, who must dose the angle of rotation of the bayonet to sufficiently raise the funnel to form a sealing contact without damaging the refractory materials in contact. The operator must necessarily be in the immediate vicinity of the pouring nozzle of the ladle, which is not ideal from a safety point of view. In addition, one operator is required to center and align the ladle nozzle over the hopper, and another operator is required to operate the lifting mechanism via a handle. Once the hopper of the protective shroud contacts the pouring nozzle, the lifting mechanism no longer moves during the entire pouring operation. This can be a problem because the flow of molten metal through the shroud causes vibrations that spread to the contact area between the pouring nozzle and the hopper, which can cause wear or even cracks in refractory materials.

[005] One of the objectives of the present invention is to provide a mold comprising a mold/shroud coupling mechanism that is easy to operate and requires less human intervention to engage the shroud funnel with the ladle pouring nozzle to form a sealing contact. In addition, one of the objectives of the present invention is to provide a casting system that is easier and safer to operate than the systems known from the prior art.

[006] Another object of the present invention is to provide a method for casting molten metals using a mold/protective cover connection mechanism of the above-mentioned type.

ESSENCE OF THE INVENTION

[007] These and other objects are achieved by the features of the independent claims. Preferred embodiments of the invention are covered by the dependent claims.

[008] In a first aspect, the invention relates to a mould for casting molten metals comprising:

• a casting cavity having a cavity inlet opening,

• a housing selected from a filter housing and a diverter housing, having a housing outlet in fluid communication with the cavity inlet, and a housing inlet in fluid communication with:

• a channel passing between the upper surface of the mold and the inlet opening of the housing,

• a mould/shroud connection mechanism configured to position the shroud of a casting machine in a shroud pouring position, wherein the shroud comprises a funnel attached to a proximal end of a shaft that is hollow and has a distal end that contains a shroud outlet, and wherein the shroud pouring position is defined as the shaft being positioned in the channel, wherein its distal end is inserted through the inlet of the housing, and the outlet of the shroud is enclosed in the housing.

[009] The form is characterized in that the mechanism for connecting the form/protective casing comprises:

• a base element fixed to the upper surface,

• a mounting element designed to receive a funnel and hold the protective casing in the position for pouring the protective casing.

[0010] The mounting element is connected to the base element by at least one flexible element in such a way that the mounting element is separated from the base element and is designed with the possibility of movement relative to it when a load is applied to the mounting element, which deforms at least one flexible element.

[0011] The compliant element may comprise one or more elastic elements defining an elastic configuration. The one or more elastic elements may comprise an elastomeric material at the process temperature or a spring, preferably a coil spring, extending between the mounting element and the base element. Alternatively, the compliant elements may comprise a bulk material enclosed in one or more bags configured to deform when a load is applied to the mounting element.

[0012] In one preferred embodiment of the invention, each of the base element and the mounting element comprises a central opening aligned with each other to define a feed to the channel for the protective cover. In the elastic configuration as defined above, the mold/protective cover connection mechanism may comprise at least three elastic elements, preferably at least three coil springs, extending between the mounting element and the base element, wherein the at least three elastic elements are preferably uniformly spaced from each other around the circumference of the central openings of the mounting element and the base element.

[0013] In a second aspect, the invention relates to an assembled form comprising:

• a form in accordance with the invention, and

• a protective casing comprising a funnel attached to a proximal end of a shaft which is hollow and has a distal end comprising a discharge opening of the protective casing, wherein the protective casing is placed in a mould, wherein the mounting element receives the funnel and holds the protective casing in a position for pouring the protective casing,

wherein the position of the pouring of the protective casing is defined as the placement of the shaft in the channel, with its distal end inserted through the inlet opening of the housing, and the outlet opening of the protective casing enclosed in the housing.

[0014] In one preferred embodiment of the assembled mould, the protective cover is fixed to the mounting element with a filling of moulding sand, sealing the annular gap between the funnel and the mounting element and defining a mounting location for the funnel, and the mounting element preferably comprises a sleeve defining the boundary of the annular gap.

[0015] In a third aspect, the invention relates to a casting apparatus comprising:

• a form in accordance with the invention, and

• a protective casing comprising a funnel attached to the proximal end of a shaft which is hollow and has a distal end comprising an outlet opening of the protective casing,

• a ladle containing a pouring nozzle provided in the base of the ladle for dispensing molten metal from the ladle, wherein the pouring nozzle is designed with the possibility of reversible and sealing engagement with the funnel of the protective casing, and wherein the ladle is designed with the possibility of displacement relative to the mold, for example,

○ positioning the pouring cup substantially vertically above the mould/protective casing connection mechanism and

○ lowering vertically until the pouring cup enters into sealing engagement with the funnel of the protective casing in the pouring position of the protective casing by applying a load to the installation element,

wherein the position of the pouring of the protective casing is defined as the placement of the shaft in the channel, with its distal end inserted through the inlet opening of the housing, and the outlet opening of the protective casing enclosed in the housing.

[0016] In the coupling configuration of the casting machine according to the invention, the casting machine comprises a ladle/guard coupling mechanism configured to reversibly couple the guard to the pouring nozzle, preferably without forming a seal between the hopper and the pouring nozzle, wherein the ladle/guard coupling mechanism comprises:

• a transition pipe of the funnel fixed to the funnel of the protective casing, wherein the transition pipe of the funnel comprises a retaining means, and

• a transition branch pipe of the pouring nozzle, fixed on the base of the ladle or on the pouring nozzle and designed with the possibility of engaging with the retaining means of the transition branch pipe of the funnel for reversible locking of the protective casing on the pouring nozzle in the locked position.

[0017] In preferred embodiments of the casting machine coupling configuration:

• the retaining means of the transition pipe of the funnel comprises retaining pins, and the transition pipe of the pouring cup comprises fastening hooks, which are designed with the possibility of reversible engagement with the retaining pins and are preferably designed with the possibility of self-engaging with the retaining pins, or

• the retaining means of the transition pipe of the funnel comprises one or more retaining pins, and the transition pipe of the pouring nozzle comprises a bayonet connection element designed with the possibility of interacting with one or more retaining pins for reversible locking of the protective casing on the pouring nozzle in the locked position.

[0018] In one preferred embodiment of the casting machine coupling configuration, the funnel transition pipe is secured to the protective casing using an adhesive material.

[0019] In one preferred embodiment of the coupling configuration, the mounting element of the mold/shroud coupling mechanism is configured to receive the transition pipe of the funnel and to hold the shroud in the position of pouring the shroud. In one preferred embodiment of the coupling configuration, the mounting element comprises a conical portion centered on the central opening of the mounting element. The conical portion is configured to guide the shroud to align with the channel when the ladle is lowered vertically, wherein the shroud is reversibly locked on the pouring nozzle.

[0020] In a fourth aspect, the invention relates to a method for casting molten metal using a casting apparatus according to the invention, comprising:

• lowering the ladle vertically until the pouring nozzle, which is engaged with the funnel, applies a load to the funnel seated on the mounting element, thus moving the mounting element relative to the base element against the pliable elements and forming a sealing contact between the pouring nozzle and the protective casing, which is in the pouring position of the protective casing,

• ensuring the flow of molten metal from the ladle into the casting cavity through the pouring nozzle, protective casing and body.

[0021] In one embodiment of the method, wherein the casting apparatus comprises a mold assembly according to the invention, the method includes engaging the pouring nozzle with the funnel by lowering the ladle vertically and forming a sealing contact between the pouring nozzle and the protective jacket by further lowering the ladle for the pouring nozzle to apply a load to the funnel.

[0022] In another embodiment of the method applied to a coupling configuration of a casting machine, the method includes:

• engagement of the pouring nozzle with the funnel of the protective casing and engagement of the protective casing with the pouring nozzle by means of a ladle/protective casing coupling mechanism by engagement:

○ a retaining means of the transition pipe of the funnel, fixed on the funnel of the protective casing, with the help of,

○ transition pipe of the pouring nozzle, fixed on the base of the ladle or on the pouring nozzle,

for example, to lock the protective cover on the pouring cup in the locked position,

• positioning the protective casing locked onto the pouring cup substantially vertically above the mould/protective casing connection mechanism,

• lowering vertically until the protective casing reaches the protective casing filling position, with the funnel resting on the installation element,

• formation of a sealing contact between the pouring nozzle and the protective casing by further lowering the pouring nozzle ladle to apply load to the funnel.

BRIEF DESCRIPTION OF GRAPHIC MATERIALS

[0023] Preferred embodiments of the present invention will now be explained in detail with reference to the accompanying drawings.

[0024] In graphic materials:

Fig. 1 shows the steps of a method for casting metal using a casting machine in accordance with one embodiment of the present invention.

Fig. 2 shows the steps of a method for casting metal using a casting apparatus according to one alternative embodiment of the present invention, comprising a ladle/shroud connection mechanism (140).

Fig. 3 shows a perspective view of an embodiment of a mold/protective casing connection mechanism according to the invention, supporting a protective casing housed therein.

Fig. 4 shows a cross-section along the lines IV-IV shown in Fig. 3 of the mold/protective casing connection mechanism and the protective casing placed therein shown in Fig. 3.

Fig. 5 shows a perspective view of a casting apparatus according to the invention, in which the pouring nozzle of the ladle is positioned vertically above the funnel of the protective casing in the pouring position of the protective casing, wherein the funnel is received in the mounting element of the mold/protective casing connection mechanism. For the sake of clarity, the ladle is not shown.

Fig. 6 is a cross-sectional view of the casting apparatus shown in Fig. 5, in which the pouring nozzle is reversibly and sealingly engaged with the funnel of the protective jacket.

Fig. 7a-7c show detailed cross-sectional views of the mechanism for connecting the mould/shroud and the pouring nozzle in the casting apparatus according to the invention, (7a) when the ladle moves over the mould, aligning the pouring nozzle with the funnel, (7b) when the ladle is lowered to bring the pouring nozzle closer to or into contact with the funnel, and (7c) when the ladle is lowered further to press the compliant members to form a sealing contact.

Fig. 8 is a bottom perspective view of a mold/protective cover connection mechanism mounting member according to one embodiment of the present invention.

Fig. 9a shows detailed cross-sectional views of a ladle/shroud coupling mechanism in a casting apparatus according to one embodiment of the present invention prior to engagement of the shroud with the pouring nozzle.

Fig. 9b is a detailed cross-sectional view of the ladle/shroud coupling mechanism in the casting apparatus shown in Fig. 9a, wherein the shroud is connected, although not hermetically, to the pouring nozzle, and the shroud is supported vertically above the mould/shroud coupling mechanism.

Fig. 9c is a detailed cross-sectional view of the ladle/shroud and mould/shroud coupling mechanism in the casting apparatus shown in Fig. 9a, wherein the hopper transition pipe is received in the mounting member of the mould/shroud coupling mechanism holding the shroud, and wherein the compliant member is in a resting state.

Fig. 9d is a detailed cross-sectional view of the mechanism for connecting the ladle/shroud and the mould/shroud in the casting apparatus shown in Fig. 9a, wherein the ladle is further lowered vertically, wherein the shroud is engaged with the pouring nozzle until the pouring nozzle applies a load to the compliant members, thus forming a sealing contact between the pouring nozzle and the shroud.

Fig. 10 shows a detailed view of the ladle/shroud coupling mechanism in the casting apparatus shown in Fig. 9a, prior to engagement of the shroud in the shroud pouring position with the pouring nozzle.

Fig. 11 shows a detailed view of the ladle/shroud coupling mechanism in the casting apparatus shown in Fig. 10, with the shroud engaged with the pouring nozzle in the shroud pouring position.

Fig. 12 is a detailed cross-sectional view of the bucket/guard coupling mechanism shown in Fig. 10.

Fig. 13 is a detailed cross-sectional view of the bucket/guard coupling mechanism shown in Fig. 11.

Fig. 14 shows a detailed view of the ladle/guard coupling mechanism in a casting apparatus according to the invention, wherein the guard is connected to the pouring nozzle and vertically moves (up or down) the ladle, and the guard is connected to it above the mold.

Fig. 15 shows a detailed cross-sectional view of a casting apparatus comprising a ladle/shroud coupling mechanism according to the invention, wherein the shroud is engaged with a pouring nozzle and is in a shroud pouring position.

Fig. 16 is a detailed cross-sectional view of the casting apparatus shown in Fig. 15, in which the protective hood is engaged with the pouring nozzle and moves vertically (up or down) above the mold.

Fig. 17a-17e show various embodiments of a compliant element according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0025] In a first aspect, the invention relates to a mould (2) for casting molten metals, as shown in Fig. 5. The mould (2) comprises one or more casting cavities (3), each of which has one or more cavity inlet openings (4), and a housing (6) selected from a filter housing and a deflector housing. The housing (6) comprises one or more housing outlet openings (6o) in fluid communication with one or more cavity inlet openings (4) of the one or more casting cavities (3). The housing (6) also comprises a housing inlet opening (6i) in fluid communication with a channel (7) extending vertically between the housing inlet opening (6i) and the upper surface (8) of the mould, where it opens into the opening. At least a part of the upper surface (8) surrounding the opening is preferably substantially flat and preferably horizontal.

[0026] In Fig. 5, the mold (2) comprises an upper part (2a) and a lower part (2b) connected horizontally along a parting line, and one casting cavity (3). The casting cavity (3) is fed from below through two inlet openings (4) of the cavity. The inlet openings (4) of the cavity communicate via two feed channels (5) with a housing (6), which is connected to a channel (7) extending to the upper surface (8) of the mold (2). The housing (6) may be a filter housing or a deflector housing. The filter housing may be constructed in the same or a similar manner as disclosed in EP 3463715 B1, which is to a certain extent incorporated herein by reference.

[0027] In Figs. 15 and 16, the mold (2) comprises several casting cavities, each of which is in fluid communication with the body (6) via corresponding feed channels (5) for transporting molten metal from the body to the casting cavities. Similarly, one and the same mold may comprise two or more channels (7) in fluid communication with one or more corresponding bodies (6).

[0028] The body (6) of the mold (2) according to the invention comprises one inlet opening (6i) of the body and one or a plurality of outlet openings (6o) of the body. It is designed with the possibility of distributing the flow of molten metal passing through the body from the inlet opening (6i) of the body to one or more outlet channels (6o) of the body connected to the casting cavities. The body (6) is selected from a diverter body and a filter body containing a filter element for filtering and removing impurities in the flow of molten metal.

MECHANISM (14) FOR CONNECTING THE FORM/PROTECTIVE CASING

[0029] During pouring, the molten metal contained in the ladle (103) is discharged through a pouring nozzle (12) located at the bottom of the ladle (103), from where it flows into the cavities (3) through the protective jacket (9), the body (6) and the feed channels (5). The protective jacket (9) comprises a funnel (11) attached to the proximal end of the shaft (10), which is hollow, wherein the channel of the protective jacket opens into the inlet opening of the protective jacket in the funnel and passes to the outlet opening (9o) of the protective jacket, opening at the distal end (10d) of the hollow shaft. To maintain the position of the protective jacket during the pouring operation, the mold according to the invention comprises a mold/protective jacket connection mechanism (14), an embodiment of which is shown in Fig. 3. As shown in Fig. 6, the mechanism (14) for connecting the mold/protective casing is designed to place the protective casing (9) of the casting machine (1) in the protective casing pouring position, defined as placing the shaft (10) in the channel (7), wherein its distal end (10d) is inserted into the housing (6) through the inlet opening (6i) of the housing in such a way that the outlet opening (9o) of the protective casing is enclosed in the housing (6). During the pouring operation, molten metal flows out of the ladle through the pouring nozzle (12), sealingly engaged with the funnel (11) of the protective casing (9) in the protective casing pouring position. The molten metal flows through the shaft (10) and enters the housing (6) through the outlet opening (9o) of the protective casing enclosed therein and exits through the outlet opening (6o) of the housing into the feed channels and fills the casting cavities.

[0030] As shown in Fig. 6, the mould (2) according to the invention is characterized in that the mould/protective cover connection mechanism (14) comprises a base element (16) attached to the upper surface (8) and a mounting element (15) configured to receive a funnel (11) and to hold the protective cover (9) in the position for pouring the protective cover. As shown in Fig. 3, the mounting element (15) is connected to the base element (16) by at least one flexible element (17) in such a way that the mounting element (15) is separated from the base element (16) when the mould/protective cover connection mechanism (14) is in a resting state and can move relative to the base element (16) and preferably in the direction of the base element (16) when a load is applied to the mounting element (15) which deforms the at least one flexible element (17).

[0031] With the mould/protective casing coupling mechanism (14) according to the invention, there is no need to manually lift the protective casing (9) received in the mounting element (15) to engage the funnel (11) with the pouring nozzle (12) of the ladle (103). In one embodiment of the present invention, the protective casing is connected to the mould in the pouring position, i.e. when the funnel rests on the mounting element (15) of the mould/protective casing coupling mechanism (14), wherein the hollow shaft is accommodated in the channel (7) and the outlet opening (9o) of the protective casing is in the housing (6). In contrast to the mould/guard coupling mechanism described in EP 3 463 715 B1, in the resting state, the funnel rests on the mounting element (15), which is held at a resting distance (h0) from the base element (16) by the counteraction force of the compliant element (17) thus displaced. The pouring nozzle (12) of the ladle (103) is engaged with the funnel (11), which rests on the mounting element (15) of the mould/guard coupling mechanism (14), simply by first moving the ladle over the mould relative to the funnel and then lowering the ladle (103) towards the mould (2) until the pouring nozzle engages with the funnel, as illustrated in Fig. 7a and 7b. In Fig. 7a, the pouring nozzle is aligned with the funnel and is located at a distance from it in the vertical direction. Then the ladle is lowered, i.e. moved downwards towards the funnel in such a way that the pouring nozzle engages with the funnel of the protective hood, as illustrated in Fig. 7b. At this stage, the pouring nozzle and the funnel are not connected in such a way as to form a sealing contact. Then, in order to sealingly engage the pouring nozzle with the funnel and to prevent air and molten metal from leaking through the contact boundary between the pouring nozzle and the funnel, the ladle is further lowered, as illustrated in Fig. 7c, in such a way that the pouring nozzle contacts the funnel and applies a load thereto, resting on the mounting element (15) of the mold/protective hood connection mechanism (14), causing the mounting element (15) to move towards the base element (16) by deforming the compliant element (17) in such a way that the connection of the pouring nozzle and the funnel can be performed in a controlled manner. As shown in Fig. 7c, the movement of the mounting element (15) relative to the base element (16), caused by the downward translational movement of the ladle and made possible by the deformation of the compliant element (17), reduces the distance between the mounting elements (15) and the base element (16) from the rest distance (h0) to the compaction distance (h1), where h1 < h0. The downward movement of the mounting element towards the base element will, of course, lead to an axial movement of the protective cover in the mold channel. This means that, since the downward movement of the mounting element (15) towards the base element (16) introduces the distal end of the protective cover and the outlet opening (9o) of the protective cover deeper into the housing, the inlet opening (6i) of the housing must allow such a movement. In addition to the means known in the art, the dynamic seal between the movable protective casing and the inlet opening (6i) of the fixed housing may be formed using an intumescent sealing material, such as a gasket, placed in the inlet opening of the housing, as described in relation to sliding dampers in WO 2013/088249 A2.

[0032] In Fig. 7a and 7b, the pouring nozzle is not in contact with the hopper or is barely in contact with it. Thus, the mould/shroud connection mechanism (14) is in a resting state, wherein the mounting element (15) is held at a fixed resting distance (h0) from the base element (16), when it is supported by the compliant element (17), which is also in a resting state under the action of gravity. In Fig. 7c, the mould/shroud connection mechanism (14) is in a loaded state, wherein the pouring nozzle is in contact with the hopper and applies a load to it, i.e. a downward force caused by the downward movement of the ladle. This load applied to the hopper is transmitted through the mounting element to the compliant element (17), which is deformed to achieve a deformed or loaded state, wherein the mounting element (15) is moved by a sealing distance (h1) from the base element (16). The counteraction force of the flexible element presses the funnel to the pouring nozzle, thus forming a sealing contact at the contact boundary of the pouring nozzle and the funnel. The presence of the flexible element (17) in the invention replaces the intervention of the operator, who manually rotates the bayonet connection and raises the funnel to engage it with the pouring nozzle, as described in the prior art. In the invention, lowering the ladle for sealing engagement of the pouring ladle with the funnel of the protective casing can be achieved by an operator controlling the position of the ladle. In addition, the action of the operator is not reproducible, and the force applied to the contact boundary between the pouring nozzle and the funnel depends on the force applied to rotate the bayonet connection. The same force is applied to the flexible element (17) during each casting operation, since it is controlled by the compliance of the flexible element.

[0033] Another advantage provided by the mechanism (14) for connecting the mould/protective cover in the mould according to the invention consists in providing displacements between the mounting element and the base elements and, thus, between the protective cover held by the mounting element and the mould, as well as absorbing the energy generated by such movements, reducing the wear caused by friction between the moving elements. For example, lowering the ladle in the vertical direction requires a high level of precision on the part of the operator giving the command to determine the position of the ladle in order to avoid impacts when engaging and contacting the pouring nozzle with the funnel, i.e. for a soft establishment of contact between the pouring nozzle and the funnel. In the absence of a compliant element, lowering the ladle too deeply or too quickly can cause serious stress, impacts or even destruction of the refractory material of the pouring nozzle and the funnel, especially at the point of contact with the pouring nozzle. The energy of such an impact is partially absorbed in the present invention due to the presence of a mechanism (14) for connecting the mold/protective casing, which provides a flexible relative displacement between the mounting elements and the base elements.

[0034] The mould/shroud connection mechanism (14) in the mould according to the present invention preferably also provides for the compensation of lateral and/or inclined displacement between the pouring nozzle and the hopper, i.e. the displacement between the pouring nozzle and the hopper in the horizontal direction. Lateral displacements may occur when the ladle is lowered to engage the pouring nozzle with the hopper of the shroud. Without a compliant element (17) in the mould/shroud connection mechanism (14), as has been the case up to now, the lateral displacement may prevent the formation of a sealing contact between the pouring nozzle and the hopper or may cause significant stresses in the material to compensate for this displacement to establish a sealing contact. In the present invention, the lateral displacement is compensated by the mould/shroud connection mechanism (14) by introducing a compliant element, thereby reducing material stresses and possible malfunctions in the casting plant. The same applies in the case of tilt or angular displacement (α), as illustrated in Fig. 6.

[0035] Similarly, the mold according to the invention, comprising a mold/protective jacket connection mechanism (14), also makes it possible to compensate for small displacements of the ladle relative to the mold and to maintain a sealing contact between the pouring nozzle and the funnel during the pouring operation. For example, such displacements are caused by the flow of molten metal through the channel of the protective jacket and by changes in the mass distribution of the molten metal retained in the ladle, as the ladle is gradually emptied of molten metal during the pouring operation, which results in the ladle being slightly tilted or moved vertically or to the side, and the pouring nozzle being in engagement with the funnel, as illustrated in Fig. 6.

[0036] As illustrated in Fig. 3, 4 and 5, each of the base element (16) and the mounting element (15) of the mold/shroud connection mechanism (14) according to the invention may comprise a central opening aligned with each other to define an inlet to the channel (7) of the shroud (9). In Fig. 3, 4 and 5, the base element (16) has a central opening (20) which has a circular shape and forms an inlet to the channel (7) through which the shroud (9) can penetrate into the channel (7) until reaching the pouring position, i.e. when the shroud funnel rests on the mounting element with the shroud outlet opening in the body (6), as shown in Fig. 5 and in the detailed cross-sectional view in Fig. 4. As will be described below, the protective cover may be inserted into the channel by a human operator, as shown in Fig. 1(1a), or by lowering the bucket with the protective cover attached thereto, as shown in Fig. 2(1) and (2).

[0037] In one embodiment of the invention, in which the protective hood is in the pouring position before the ladle is lowered to establish contact between the pouring nozzle and the funnel (cf. Fig. 1(1a) and (1) and 7a), the mounting element (15) is formed by a sleeve (21) provided with levers (18) distributed over the circumference of the sleeve and extending radially outward from it, as illustrated in Fig. 3 and 4. The sleeve (21) forms a through feed for guiding the protective hood (9) into the pouring position. In the resting state, the sleeve is concentrically aligned with the central opening (20) of the base element (16). As shown in Fig. 4 and 7a, to fix the funnel on the mold (2), the space between the through-feed of the sleeve and the funnel can be filled with filling (22), preferably made of molding sand, forming a mounting place on which the projection (23) of the funnel (11) rests when the protective casing (9) is in the pouring position.

[0038] The filling (22) with molding sand may contain an organic binder, such as furan, alkali-phenolic binders. Other binders, such as inorganic binders or clay minerals, may also be used. The filling defines the mounting location for the conical projection (23) of the funnel and at the same time ensures a seal and fixes the protective cover on the mold (2).

[0039] In the pouring position of the protective casing, the funnel is preferably located flush with the upper edge of the sleeve, as illustrated in Fig. 4, or, alternatively, may be recessed into the sleeve (21) below the upper edge.

[0040] One preferred embodiment of the mold/protective casing connection mechanism (14) according to the invention is shown in Fig. 3. It comprises a mounting element (15) configured to receive and hold a funnel (11). The mounting element is connected to a base element (16) by means of compliant elements (17) in the form of coil springs (17s). The mounting element (15) has three radially outwardly extending levers (18) that are uniformly spaced from each other at a radial distance from the axis of symmetry of the through feed. A person skilled in the art may understand that the mounting element may have any other shape, for example it may have the shape of a disk, and the number of outwardly extending levers may vary.

[0041] The base element (16) is preferably rigidly attached to the upper surface (8) of the mold (2). For example, the base element can be connected by an adhesive (organic or mineral) or by fastening means such as screws, rivets, etc. This ensures that the central opening (20) of the base element remains concentric with the channel (7) during the entire casting operation. The base element also comprises three radially outwardly extending levers (18), which are uniformly spaced from each other at a radial distance from the axis of symmetry of the central opening (20) and are aligned with the corresponding opposite levers of the mounting element (15). The flexible element (17) is formed by three spiral springs (17s) located between the mounting element and the base element.

[0042] Referring to Fig. 3, three coil springs (17s) extend vertically between three pairs of opposite arms (18) of the mounting member (15) and the base member (16). The coil springs (17s) are evenly distributed around the circumference of the mounting member (15) and the base member (16). The arms (18) are provided with centering pins (19) for centering and holding the coil springs in place, as illustrated in the detailed view in Fig. 4 and 8. The centering pins (19) of the mounting element (15) and the centering pins (19) of the base element (16) extend in opposite directions and are aligned with each other in such a way that each of one centering pin (19) of the base element (16) and a correspondingly located centering pin (19) of the mounting element (15) is engaged with one end of the coil spring (17s) on opposite sides. In this configuration, the mounting element (15) is supported on the base element by three coil springs (17s) with the possibility of movement.

[0043] When the protective casing (9) with the funnel (11) is in the pouring position, resting on the mounting element (15), the spiral springs (17s) are in a resting state such that there is a vertical resting distance (h0) between the mounting element (15) and the base element (16) (see Figs. 4 and 7b).

[0044] When the metal is to be poured into the casting cavity (3), the ladle is centered over the mold (2) in such a way that the pouring nozzle (12) of the ladle is aligned with the funnel (11). Then the ladle (103), suspended by the crane, is lowered and the pouring nozzle (12) engages with the funnel (11), thereby applying a downward force that vertically displaces the mounting element (15) towards the base element (16). This vertical displacement is made possible by the deformation of the flexible elements (17) (in this case by compression of the spiral springs).

COMPLIANT ELEMENT (17)

[0045] In the mould according to the invention, the mounting element (15) is connected to the base element (16) by at least one flexible element (17) in such a way that the mounting element (15) is separated from the base element (16) and is designed to move relative to it when a load is applied to the mounting element (15), which deforms the at least one flexible element (17). In particular, when a load or force is applied vertically and downwards, when the ladle is lowered and the pouring nozzle (12) is pressed against the funnel (11) of the protective casing received in the mounting element (15), the flexible element (17) is designed to move from a state of rest, as illustrated in Fig. 7b, in which a vertical distance of rest (h0) separates the mounting element (15) from the base element (16), to a loaded or deformed state, as illustrated in Fig. 7c, in which the vertical distance separating the mounting element (15) from the base element (16) is reduced to a sealing distance (h1), wherein h1 < h0. This means that the mounting element (15) moves towards the base element (16) or closer to it in the vertical direction when a vertical and downward force is applied by the pouring nozzle to the funnel of the protective casing.

[0046] Furthermore, the flexible element (17) in the mold/protective casing connection mechanism (14) according to the invention can be designed with the possibility of lateral displacements of the mounting element (15) relative to the base element (16), i.e. relative displacements between the mounting element and the base elements in the horizontal direction perpendicular to the vertical direction.

[0047] In the mold/protective casing connection mechanism (14) according to the present invention, the compliant element (17) may be at least partially elastic such that, in a deformed or loaded state, it counteracts a counteracting force tending to restore at least partially the resting state of the mold/protective casing connection mechanism (14). This includes compliant elements (17) exhibiting elastic behavior (such as spiral springs (17s) made of steel) or viscoelastic behavior, with an elastic modulus (E’) and a loss modulus (E”). For example, when a ladle pouring nozzle applies a vertical and downward load to the hopper, received in the mounting element, to bring the mounting element (15) downwards by a sealing distance (d1) from the base element (16), the reaction force of the loaded compliant element (17) may tend, after the load is removed, to bring the mounting element (15) at least partially to the initial rest distance (d0) from the base element (i.e. to a distance h such that h1 < h ≤ h0). Such an elastic element is preferable since it is suitable for maintaining the sealing contact between the hopper and the pouring nozzle during pouring, as well as in the case of slight movement of the pouring nozzle up and down due to vibrations during pouring. In general, a compliant member that is elastic is therefore more suitable for use in cases where the pouring nozzle, which is in sealing engagement with the funnel of the protective jacket, moves or vibrates during the pouring operation.

[0048] Alternatively, the flexible element (17) may exhibit purely plastic or viscous behavior such that after the load is removed it cannot restore, even partially, its original geometry. For example, this is the case of a flexible element designed to undergo a substantially plastic deformation when a load is applied. This may also be the case of flexible bags or containers containing bulk material, such as a particulate material (e.g. sand or the like), which can absorb energy by counteracting the viscous flow to the load applied by the pouring nozzle to the protective casing and the mounting element.

[0049] The mechanism (14) for connecting the mold/protective casing may comprise one or more flexible elements (17) extending between the mounting element (15) and the base element (16) and separating them from each other in the vertical direction. Preferably, the one or more flexible elements (17) comprise one or more elastic elements comprising an elastomeric material at the process temperature or a spring, preferably a coil spring (17s), as illustrated in Fig. 3.

[0050] In a first embodiment of the invention, shown in Fig. 17a, the elastic element is designed to extend when moving from a rest state to a deformed or loaded state of the elastic element, corresponding to a rest state or a loaded state of the mold/protective casing connection mechanism, respectively. It is called a "tensile-elastic element". The tension-elastic element is preferably an extensible spring, as illustrated in Fig. 17a.

[0051] In a second embodiment of the invention shown in Figs. 17b-17d, the elastic element is designed to be compressed when moving from a rest state to a deformed or loaded state of the elastic element, which corresponds to a rest state or a loaded state of the mold/protective casing connection mechanism, respectively. It is called a "compression-elastic element". The compression-elastic element is preferably a compressible spring, preferably a coil spring (see Fig. 17b), a compressible hydraulic or pneumatic piston (see Fig. 17c) or a compressible elastomeric or predominantly viscoelastic element (see Fig. 17d).

[0052] In a third embodiment of the invention, shown in Fig. 17e, the elastic element is designed to bend when moving from a state of rest to a deformed state of the elastic element. It is called a "flexurally elastic element". The flexible element may preferably comprise a curved blade or rod and is preferably made of steel or a fiber-reinforced composite material attached at one or two points, as illustrated in Fig. 17e.

[0053] In an alternative embodiment, the flexible element (17) comprises a bulk material enclosed in one or more bags or flexible containers designed to undergo viscous deformation when a load is applied to the mounting element (15). The flexible element may also comprise disposable elements designed to be destroyed or crushed by plastic deformation when a load is applied to the funnel by the pouring nozzle.

[0054] Preferably, the mould/protective casing connection mechanism (14) comprises at least three elastic elements, preferably at least three coil springs (17s), extending between the mounting element (15) and the base element (16), wherein the at least three elastic elements are preferably uniformly spaced from each other along the circumference of the central openings of the mounting element (15) and the base element (16), as illustrated in Figs. 3, 4 and 5. Preferably, the at least three coil springs, which are preferably uniformly spaced from each other, extend between said mounting element and said base element along their circumference and at a distance from the inlet to said hollow shaft of the protective casing. The advantage of this design is that the coil springs will not be excessively heated by the molten metal flowing through the channel of the protective casing from the funnel to the hollow shaft of the protective casing during the casting process.

ASSEMBLED FORM

[0055] In another aspect, the invention relates to an assembled mould comprising a mould (2) according to the invention as described above and a protective casing (9) in a pouring position, wherein the funnel rests on a mounting element (15). The protective casing comprises a funnel (11) attached to a proximal end of a shaft (10) which is hollow and has a distal end (10d) comprising an outlet opening (9o) of the protective casing. The pouring position of the protective casing is defined as a position in which the shaft (10) is received in the opening (7), wherein its distal end (10d) is inserted through the inlet opening (6i) of the housing, wherein the outlet opening (9o) of the protective casing is enclosed in the housing (6).

[0056] Preferably, the funnel is located outside the mold, i.e. above the upper surface (8) of the mold and next to it, and the shaft (10) is received in said channel (7) and is designed with the possibility of moving up and down in it. The shaft is elongated and extends in a vertical direction so that the molten metal can flow through it under the action of gravity. The outlet opening (9o) of the protective casing may comprise one or more openings for dispensing molten metal in the body (6).

[0057] In the position of pouring the protective jacket, as shown in Fig. 5, the hollow shaft passes through the entire channel (7) into the body (6). The molten metal is fed into the casting cavity (3) through the line of the protective jacket, passing from the ladle to the casting cavities, including the pouring nozzle, the protective jacket, the body and the feed channel (5). The line of the protective jacket is substantially airtight and prevents re-oxidation of the metal by protecting it from the atmosphere. The hollow shaft (10) feeds the molten metal through the body (6) and through the feed channels (5) through the inlet openings (4) into the casting cavity (3). The channel (7), which passes substantially perpendicular to the upper surface (8) of the mold (2), is sized to receive the protective jacket (9) in such a way that there is substantially no gap between them, while ensuring linear movement of the protective jacket (9) in the channel (7). The open bushing (13) of the feeder, which passes between the casting cavity (3) and the upper surface (8) of the mould (2), communicates via a fluid medium with the casting cavity (3)

[0058] The protective casing (9) is made of a refractory material, such as, for example, fused quartz. Alternatively, the protective casing may be made of other materials, such as alumina-graphite materials. Preferably, the proximal end of the protective casing (9), which forms a funnel (11), has a conical shape with inclined projections (23), which rest on the mounting element (15). In one embodiment of the invention, the projection rests on a filling (22), filling the space between the sleeve of the mounting element (15) and the funnel, as can be seen in the cross-sectional view in Fig. 4. Alternatively, the projection of the protective casing rests directly on the mounting element, as shown in Figs. 9c, 9d, 12 and 13.

[0059] In one preferred embodiment of the assembled mould according to the invention, the protective cover (9) is fixed on the mounting element (15), preferably with a filling (22) of moulding sand, sealing the annular gap between the funnel (11) and the mounting element (15) and defining a mounting place for the funnel (11), and the mounting element (15) preferably comprises a sleeve (21) defining the boundary of the annular gap, as illustrated in Fig. 4.

[0060] In one preferred embodiment of the present invention, a gasket is arranged at the mouth of the funnel (11) to ensure a substantially tight engagement between the pouring nozzle (12) and the funnel (11). The gasket may, for example, be formed from plasticized clay or an intumescent material.

CASTING PLANT

[0061] In another aspect, the invention relates to a casting apparatus comprising a mould (2) according to the invention, a protective casing (9) and a ladle (103) comprising a pouring nozzle (12) provided in the base of the ladle (103) for discharging molten metal from the ladle. The pouring nozzle (12) is configured to reversibly and sealingly engage with a funnel (11) of the protective casing (9). The ladle (103) is configured to be displaceable relative to the mould (2), for example for positioning the pouring nozzle (12) substantially vertically above the mould/protective casing connection mechanism (14) and lowering vertically until the pouring nozzle (12) enters into sealing engagement with the funnel (11) of the protective casing (9) in the pouring position of the protective casing by applying a load to the mounting element (15). The casting installation may comprise a gasket, which is preferably located in a funnel. In the casting installation, the protective cover (9) may be fixed to the mounting element, preferably with the filling (22), or may be designed to be detached from the mounting element (15) or removed from it.

[0062] As can also be seen in Fig. 6, the pouring nozzle of the ladle preferably has a hemispherical shape and the funnel (11) has a corresponding shape. The funnel and the pouring nozzle preferably have a complementary shape, for example by forming mating spherical caps or otherwise curved surfaces so that the tilt of the ladle can be tolerated within certain limits. If the compliant elements (17) comprise an elastic element, such as coil springs, the reaction force of the compliant element also ensures that the pouring nozzle (12) and the funnel (11) are held in sealing engagement with each other during pouring. The reaction force exerted by the compliant element ensures that the pouring nozzle and the funnel are held in sealing engagement with each other, and that sufficient pressure is always maintained on the sealing surface or on the gasket inside the funnel. The compliant element can also compensate for any tilt or up and down oscillation of the ladle that may occur due to the ladle's centre of gravity changing during pouring, i.e. during ladle emptying.

[0063] The funnel and the pouring nozzle are preferably designed in such a way that the pouring nozzle is self-centering within the funnel. For example, the surface of the funnel designed to receive the pouring nozzle may have a conical shape, as shown in Figs. 3 and 4, so that when the ladle (103) is lowered vertically to engage the pouring nozzle with the funnel, wherein the pouring nozzle is not perfectly aligned with the funnel, the pouring nozzle (12) can slide along the surface of the conical shape and apply a force to the mounting element (15) to shift the mounting element in the horizontal direction and restore alignment between the pouring nozzle and the funnel and, ultimately, sealing engagement of the pouring nozzle in the funnel.

MECHANISM (140) CONNECTING BUCKET / PROTECTIVE CAP

[0064] A preferred embodiment of the casting apparatus according to the invention comprises a ladle/shroud coupling mechanism (140) configured to reversibly engage the shroud (9) with the pouring nozzle (12), preferably without forming a seal between the funnel (11) and the pouring nozzle (12).

[0065] As illustrated in Fig. 2 and 9a, this allows the ladle to be moved with the protective cover suspended therefrom, which is advantageous when the protective cover can be reused for several castings in a row, for example as illustrated in Fig. 2. When performing a series of subsequent castings using the same ladle and protective cover (9), the protective cover can be, for example, disengaged from the channel of the first mold after the casting of metal in the first mold is completed by lifting the ladle upwards (see Fig. 2, step 4). The ladle is then successively moved horizontally to position the protective cover above the channel of the second mold (see Fig. 2, step 5). The ladle is then lowered downwards (see Fig. 2 - step 1) until the protective cover reaches the pouring position (see Fig. 2, step 2) and a subsequent casting can be performed into the second mold. This operation can be repeated as long as the protective hood is in the pouring states. After this, the used protective hood can be removed (see Fig. 2, step 1b) and a new protective hood can be loaded into the ladle (see Fig. 2, step 1a). This ladle/protective hood connection mechanism allows the same protective hood to be used repeatedly for several pourings. It also reduces the operator's workload since the connection between the ladle, the protective hood and the mould can be individually performed by the operator giving commands to the ladle positioning system. Between two pourings using the same protective hood, the protective hood, heated by the previous pouring in the mould, does not require manipulation by the operator to position it in the pouring position in the subsequent mould, thus increasing safety.

[0066] As shown in Fig. 9a, the ladle/guard connection mechanism (140) comprises a hopper adapter (140f) which is fixed to the hopper of the guard (9) and comprises retaining means. The hopper adapter (140f) is typically made of metal and is fixed to the projection of the guard using an adhesive filler (113), such as cement, etc. The ladle/guard connection mechanism (140) also comprises a nozzle adapter (140n) which is fixed to the ladle base (103) or to the pouring nozzle (12) and is configured to engage with the retaining means of the hopper adapter (140f) for reversibly locking the guard (9) on the pouring nozzle (12) in the locked position. The unlocked and locked positions of the mechanism (140) for connecting the ladle/protective casing are shown in Figs. 10 and 11, respectively. The ladle base is the lowest part of the ladle in use. The transition pipe (140n) of the pouring nozzle is preferably mounted on the base of the stop ladle.

[0067] The transition branch (140f) of the funnel and the transition branch (140n) of the pouring nozzle complement each other and are designed to be detachably and freely engaged with each other in the locked position. One important aspect of the mechanism (140) for connecting the ladle / protective casing according to the invention is that the transition branch (140f) of the funnel and the transition branch (140n) of the pouring nozzle are designed to be freely engaged with each other in the locked position. This means that the transition branches of the funnel and the pouring nozzle engage with each other in the locked position with a sufficient clearance relative to each other, so that they can be pivotally rotated to a certain extent relative to each other within certain limits. This design ensures the relative movement of the protective casing and the ladle, when the protective casing is attached to the ladle in such a way that the risk of damage to the protective casing when inserting, for example, into the mold channel is significantly reduced. In the locked position, it is preferable that no sealing contact is formed between the pouring cup and the funnel.

[0068] In one preferred embodiment of the ladle/shroud coupling mechanism shown in Figs. 10 and 11, the holding means of the transition pipe (140f) of the funnel comprise holding pins (109), and the transition pipe (140n) of the pouring nozzle comprises fastening hooks (107) configured to reversibly engage the holding pins (109) and preferably configured to self-engage with the holding pins (109). The self-engaging fastening hooks ensure easy engagement of the shroud with the ladle. For example, this allows the ladle to be used to pick up the shroud held in the pouring position in the first mold (2) according to the invention, as illustrated in Fig. 10, by lowering the ladle to engage the retaining means of the transition pipe of the funnel with the transition pipe of the pouring nozzle, as illustrated in Fig. 11 and 15, and then raising the ladle to remove the protective casing from the channel, as illustrated in Fig. 14 and 16.

[0069] Again, with reference to Fig. 12, the transition pipe (140f) of the funnel may be a sleeve-shaped element that has a truncated supporting surface (114) resting on an inclined edge (115) in the central opening (25) of the mounting element (15), forming a mounting place for the transition pipe (140f) of the funnel. The transition pipe (140f) of the funnel sits freely in the mounting element (15) and is held only by gravity, that is, by the weight of the protective casing (9), which is suspended from the transition pipe (140f) of the funnel.

[0070] Along the outer circumference of the transition pipe (140f) of the funnel, three or four retaining pins (109) extend outward in the radial direction. The retaining pins (109) can be engaged by means of fastening hooks (107) attached to the transition pipe (140n) of the pouring nozzle, which is attached to the base plate (105) of the ladle.

[0071] The transition pipe (140n) of the pouring nozzle is designed as a nest surrounding the pouring nozzle (12). On the side attached to the ladle (103), also called the proximal side, the first connecting element (11) comprises a bayonet ring (106) engaged with the plate (105) of the ladle base. The transition pipe (140n) of the pouring nozzle is removably connected to the ladle (103). At the other end of the transition pipe (140n) of the pouring nozzle, also called the distal end, the transition pipe (140n) of the pouring nozzle comprises a plurality of pins (111), to which fastening hooks (107) are rotatably attached.

[0072] When the pouring nozzle (12) is lowered into the funnel (11), the transition pipe (140n) of the pouring nozzle and the transition pipe (140f) of the funnel engage with each other. The connection and locking of the transition pipes of the pouring nozzle and the funnel can be carried out in various ways. The fastening hooks (107) can be self-engaging. The inclined surface (112) of the fastening hooks (107) slides along the retaining pins (109) in such a way that the fastening hooks (107) engage with the retaining pins (109).

[0073] In an alternative embodiment, the transition pipe (140f) of the hopper can be rotated in such a way that when the bucket (103) is lowered, the retaining pins (109) are positioned between the fastening hooks (107), and then when the transition pipe (140f) of the hopper is rotated, for example, the retaining pins (109) are locked counterclockwise inside the fastening hooks (107).

[0074] Once connected as shown in Fig. 13, the ladle (103) with the protective cover (9) suspended on the ladle can be lifted for insertion into the second mold for a second casting using the same protective cover.

[0075] In another embodiment of the bucket/guard connection mechanism (140), the retaining means of the transition pipe (140f) of the funnel comprises one or more retaining pins (109), and the transition pipe (140n) of the pouring nozzle comprises a bayonet connection element adapted to interact with one or more retaining pins for reversibly locking the guard (9) on the pouring nozzle (12) in the locked position.

[0076] The transition pipe (140n) of the pouring nozzle may have the form of a sleeve-shaped element, which at one end and/or at both ends may be designed as a bayonet connection element. The transition pipe (140n) of the pouring nozzle may contain the pouring nozzle and may be removably attached to the base plate (105) of the ladle, as illustrated in Figs. 12 and 13. For example, at one end, the transition pipe (140n) of the pouring nozzle may be designed as a bayonet ring (106) engaged with a corresponding structure on the base plate of the ladle.

[0077] In one particularly preferred embodiment of the ladle/shroud coupling mechanism according to the invention, the hopper transition pipe and/or the nozzle transition pipe are rotatable about a longitudinal axis to ensure at least disengagement of the hopper and the nozzle transition pipes by rotating either the hopper or the nozzle transition pipe about said longitudinal axis.

[0078] In the casting apparatus according to the invention, the mounting element (15) of the mould/protective casing connection mechanism (14) is designed to receive the transition pipe (140f) of the funnel and to hold the protective casing (9) in the position for pouring the protective casing.

[0079] The transition pipe (140f) of the funnel is preferably fixed to the protective casing (9) by means of an adhesive material (113), as shown in Figs. 12 and 13. Preferably, the proximal end of the protective casing in the region of the funnel can have the shape of a truncated cone, the projections (23) of which are held in the adhesive material (113), which is preferably a filling or packing of molding sand of the transition pipe of the funnel, which, for example, can contain an organic binder. The transition pipe of the funnel can be designed as a sleeve-shaped element. The transition pipe of the funnel is preferably surrounded by an adhesive material (113).

[0080] The transition pipe (140f) of the funnel can be designed to be received in the mounting element (15) on the mold (2) at the center. Therefore, the transition pipe of the funnel can comprise a truncated support surface.

[0081] Preferably, the casting apparatus according to the invention provides for the connection of the ladle with the protective hood in situ, i.e. when the protective hood is inserted into the mold. In this way, a separate fastening stand for the ladle is not required. This system allows the protective hood to be inserted into the mold using a separate crane. As soon as the protective hood is inserted into the mold, the ladle can be positioned above the mold, wherein the pouring nozzle is centered over the funnel of the protective hood. When the ladle is lowered, the pouring nozzle can be brought into engagement with the funnel of the protective hood. When the pouring nozzle of the ladle is engaged with the funnel, the funnel and the transition pipes of the protective hood can be locked with each other in such a way that the ladle and the protective hood are freely locked with each other.

[0082] It will be understood by a person skilled in the art that the downward force when lowering the pouring nozzle of the ladle into the hopper will result in the movement of the mounting element towards the base element opposite to the counteracting force of the compliant element, preferably opposite to the spring tension of at least one spring, so that the connection of the pouring nozzle and the hopper can be carried out in a controlled manner. The downward movement of the support element towards the base element will, of course, result in an axial movement of the protective jacket within the mold channel. For example, if the distal end of the protective jacket extends into the mold body, the downward movement of the mounting element towards the base element causes the distal end of the protective jacket to extend deeper into the body, where at least one outlet opening (9o) of the protective jacket communicates with the mold runner system, i.e. with the casting cavity, via the feed channels (5).

[0083] In the prior art, the so-called Harrison process, as proposed by the Harrison Steel Castings Company, involves attaching a fused silica guard under the pouring nozzle of a stopper ladle. The mold is provided with a side mold for receiving the guard. A drain well is provided under the side mold, which feeds the casting cavity. With the guard attached, the ladle above the mold is aligned with it and then lowered so as to insert the guard into the side mold. The stopper rod is then moved to the open position so that the molten metal flows with the help of the ladle through the pouring nozzle and the guard into the mold. After filling the mold, the stopper is closed. The ladle is raised until the guard is removed from the mold, and then moved from above to the next mold to repeat the process. To attach the guard under the pouring cup of the stopper ladle, the ladle is first secured to the mounting post, and then the guard is fixedly attached to the guard holder assembly, which is connected to the base plate of the ladle.

[0084] One of the disadvantages of the said rigid and fixed attachment of the protective cover to the pouring nozzle is that cleaning the pouring nozzle with an oxygen lance is practically impossible. Since fused quartz is chosen as the material of the protective cover, inserting the protective cover into the side mold of the mold when attaching to the bottom of the ladle is a complex and critical manipulation, since even the slightest tilt of the protective cover can lead to destruction of the protective cover.

[0085] In the invention, the previous disadvantage can be avoided by freely engaging the protective cover with the ladle and providing a flexible element that allows relative displacements between the mounting element and the base elements of the mold/protective cover connection mechanism (14). This reduces the risk of destruction of the protective cover when inserting it into the mold and thus provides a safer system for handling the protective cover for obtaining several castings using one protective cover at one high casting temperature.

[0086] To further increase the safety of engagement of the protective casing engaged with the ladle in the mould channel, the mounting element (15) preferably comprises a conical portion centred on the central opening of the mounting element, wherein the conical portion is designed to guide the protective casing for alignment with the channel (7) when the ladle (103) is lowered vertically, wherein the protective casing (9) is reversibly locked on the pouring nozzle (12).

METHOD WITHOUT USING THE MECHANISM (140) FOR CONNECTING THE BUCKET / PROTECTIVE CASING

[0087] The invention also relates to a method for casting molten metal using a casting apparatus according to the invention.

[0088] In the first embodiment of the method illustrated in Fig. 1, the casting machine does not comprise a ladle/protective cover connection mechanism (140), and the protective cover is inserted into the channel (7) in the pouring position before the ladle approaches the mold. As shown in step 1a in Fig. 1, a casting machine is proposed that comprises a mold (2) and a protective cover (9) inserted into it to achieve the pouring position. Preferably, the axis of symmetry of the channel opening is vertical when the mold is set for operation, and the protective cover is installed in the channel by its translational movement in the vertical direction. The protective cover (9) can be inserted into the mold (2) by an operator, as illustrated in Fig. 1(1a), or using one or more special devices or a robot. As illustrated in Fig. 5, the shaft (7) is inserted into the channel (7) of the mold until the protective casing is set in the pouring position, defined as the placement of the shaft (10) in the channel (7), wherein its distal end (10d) is inserted through the inlet opening (6i) of the housing, and the outlet opening (9o) of the protective casing is enclosed in the housing (6). In the pouring position of the protective casing, the longitudinal axis of the hollow shaft (10) is preferably vertical. The protective casing (9) is held in the pouring position of the protective casing by means of the mounting element (15), on which the funnel (11) rests.

[0089] In an example according to the invention, the funnel of the protective casing comprises a projection for mounting the funnel on the mounting element (15), and wherein the funnel is placed directly on the mounting element (15) and the protective casing is detachably held in the position of pouring the protective casing under the action of gravity. In another example, a filling (22) is provided between the funnel and the mounting element (15). The protective casing (9) is fixed on the mounting element (15) by means of the filling (22), sealing the annular gap between the funnel (11) and the mounting element (15) and defining the mounting place for the funnel (11). Preferably, the mounting element (15) comprises a sleeve (21), defining the boundary of the annular gap, and the filling (22) can be applied to the sleeve (21) before the funnel is received by the filling (22) and mounted on it. The filling must then dry until the funnel is fixed onto the mounting element (15).

[0090] After step 1a in Fig. 1, the mold assembly is ready to receive molten metal. As illustrated in step 1 in Fig. 1 and in the detail view in Fig. 7a, the ladle (103) loaded with molten metal is brought over the first mold loaded with a protective shroud, for example by means of a crane, and until the pouring nozzle at the base of the ladle is vertically aligned with the mold/protective shroud connection mechanism (14) and with the channel (7). Then, the ladle (103) is lowered until the pouring nozzle (12) engages with the funnel of the protective shroud (9), as illustrated in Fig. 7b. Before contact and application of the load to the funnel with the pouring cup, the mechanism (14) for connecting the mould/protective casing and the flexible element are in a state of rest, wherein the mounting element and the base elements are separated by a rest distance h0, measured in the vertical direction.

[0091] The method then includes the step of further lowering the ladle (103) vertically until the pouring nozzle (12), which is engaged with the funnel (11), applies a load to the funnel seated on the mounting element (15), thus moving the mounting element (15) relative to the base element (16) against the compliant elements (17) and forming a sealing contact between the pouring nozzle (12) and the protective jacket (9), which is in the pouring position of the protective jacket. This is illustrated in step 2 in Fig. 1 and in the detailed view in Fig. 7c, wherein the mold/protective jacket connection mechanism (14) and the compliant element are in a loaded state, wherein the mounting element and the base elements are separated by a sealing distance h1 < h0, measured in the vertical direction.

[0092] After the sealing contact between the pouring nozzle (12) and the funnel (11) has been established, the pouring of the molten metal can begin. The pouring nozzle is opened, thereby allowing the flow of molten metal from the ladle (103) into the casting cavity (3) through the pouring nozzle (12), the protective jacket (9) and the body (6) of the first mold. Once the casting cavity is filled, as illustrated in step 3 in Fig. 1, the pouring nozzle can be closed to stop the flow of molten metal.

[0093] As illustrated in step 4 of Fig. 1, after the end of pouring, the ladle is lifted vertically to disengage the pouring nozzle from the funnel of the protective cover, thereby relieving the load from the pouring nozzle on the mounting element (15). The protective cover does not engage with the ladle and remains inserted into the first mold, wherein the funnel is held by the mounting element, and the shaft is received in the channel (7). If the compliant element does not comprise an elastic element, the mold/protective cover connection mechanism (14) and the compliant element remain in a loaded state, and the protective cover does not move when the ladle is lifted. If the compliant element comprises an elastic element, the mold/protective cover connection mechanism (14) and the compliant element can return at least partially to a resting state when the ladle is lifted, and the protective cover, held by the mounting element, can accordingly slide upward within the channel.

[0094] The ladle is then available for subsequent casting into a second mould, preferably another casting at the same high temperature, as illustrated in Fig. 1, step 5, wherein the ladle is moved forward horizontally over the second mould to perform the next casting according to the present method according to the invention, wherein the ladle does not comprise a ladle/protective shroud connection mechanism (140).

METHOD USING A MECHANISM (140) FOR CONNECTING A BUCKET/PROTECTIVE CASING

[0095] In a second embodiment of the method according to the invention, the casting installation comprises a ladle/protective casing connection mechanism (140). Such a method is illustrated in Fig. 2. For casting, the first and second moulds (2), a protective casing (9) with a transition pipe (140f) of the funnel fixed thereto and a ladle with a transition pipe (140n) of the pouring nozzle fixed to its base or pouring nozzle are provided. There are at least two methods of initialising casting using the casting installation comprising the ladle/protective casing connection mechanism (140).

[0096] In the first method of initializing casting, illustrated in Fig. 2, step 1a, the protective cover is engaged with the ladle before the protective cover is inserted into the first mold. For example, this can be accomplished by the operator lifting the protective cover toward the base of the ladle to engage the funnel (11) of the protective cover (9) over the pouring nozzle (12) and engaging the protective cover (9) with the pouring nozzle (12) using the ladle/protective cover coupling mechanism (140) by engaging:

• a retaining means of the transition pipe (140f) of the funnel, fixed on the funnel of the protective casing (9), using

• transition pipe (140n) of the pouring nozzle, fixed on the base of the ladle (103) or on the pouring nozzle (12),

for example, to lock the protective cover (9) on the pouring cup (12) in the locked position.

[0097] Alternatively, the ladle may be moved above the storage location of the guard (9) and picked up by lowering the ladle with the pouring nozzle vertically aligned with the hopper until the pouring nozzle engages with the hopper and the guard (9) is engaged with the pouring nozzle (12) by means of the ladle/guard coupling mechanism (140).

[0098] Once the guard is engaged with the bucket, the bucket can be moved to:

• positioning the protective casing (9) locked onto the pouring nozzle (12) substantially vertically above the mould/protective casing connection mechanism (14), as illustrated in step 1 of Fig. 2 and in Fig. 9B, and then

• lowering the ladle vertically until the protective casing (9) reaches the protective casing pouring position, wherein the funnel (11) rests on the mounting element (15), as illustrated in Fig. 9c and Fig. 2, step 2.

[0099] Preferably, the funnel is supported on the mounting element (15) via the transition pipe (140f) of the funnel, i.e. the transition pipe (140f) of the funnel is fixed on the funnel and received into the mounting element (15) of the mold/protective casing connection mechanism (14), as illustrated in Fig. 9c, wherein the conical part of the mounting element (15) is designed with the possibility of mating with the corresponding conical part of the transition pipe (140f) of the funnel.

[00100] The sealing contact between the pouring nozzle (12) and the protective casing (9) in the pouring position of the protective casing is formed by further lowering the ladle (103) vertically until the pouring nozzle (12), which is engaged with the funnel (11), applies a load to the funnel seated on the mounting element (15), thus moving the mounting element (15) relative to the base element (16) against the compliant elements (17). This is illustrated in step 2 shown in Fig. 2 and Fig. 9d.

[00101] In the second method of initializing the pouring, the protective casing (9) is inserted into the first mold in the pouring position until it engages with the ladle. The engagement of the protective casing occurs by lowering the pouring nozzle toward the funnel, and the sealing contact is formed by moving the pouring nozzle further downwards, overcoming the resistance exerted by the compliant element (17), as illustrated in Fig. 2(2a) and (2), 10 and 12. Preferably, before forming the sealing contact, the ladle and the protective casing are not only detachably but also freely locked with each other.

[00102] In the second method of initializing the pouring, illustrated in Fig. 2, step 2a, the sealing contact between the pouring nozzle (12) and the protective cover (9) in the pouring position of the protective cover is formed after the protective cover has engaged with the ladle. This is achieved by further lowering the ladle (103) vertically until the pouring nozzle (12), which is engaged with the funnel (11), applies a load to the funnel seated on the mounting element (15), thus moving the mounting element (15) relative to the base element (16) against the compliant elements (17), as illustrated in step 2 in Fig. 2 and in Fig. 9d.

[00103] After establishing a tight contact between the pouring nozzle (12) and the funnel (11) in accordance with the first or second methods of initializing the pouring, the pouring nozzle is opened, thereby allowing the molten metal to flow from the ladle (103) into the casting cavity (3) through the pouring nozzle (12), the protective jacket (9) and the body (6) of the first mold. After the pouring is completed or the casting cavity is filled, as illustrated in step 3 in Fig. 2, the pouring nozzle can be closed to stop the flow of molten metal.

[00104] As illustrated in step 4 of Fig. 2, after the casting is completed, the ladle with the protective casing engaged therewith is raised vertically, the protective casing is disengaged from the first mould, and the load from the pouring nozzle on the mounting element (15) is removed.

[00105] The ladle with the protective jacket connected thereto is then available for subsequent casting into a second mould at the same high temperature, as illustrated in step 5 in Fig. 2, wherein the ladle is translated horizontally over the second mould to perform the next casting in accordance with the method of the present invention, wherein the ladle comprises a ladle/protective jacket coupling mechanism (140). Alternatively, at the end of a series of castings or in the event of a protective jacket failure, no subsequent casting is performed and the ladle is transported with the protective jacket connected thereto to a place of disassembly of the plant, where it is separated from the ladle. The interlock of the protective hood (9) and the pouring nozzle (12) is released by disengaging the holding means of the transition pipe (140f) of the funnel from the transition pipe (140n) of the pouring nozzle, and the funnel and the transition pipe (140f) of the funnel are preferably disconnected in such a way that the transition pipe (140f) of the funnel can be reused later and fixed on other protective hoods. The new protective hood can be used to continue casting in a number of new moulds.

List of reference positions

1 Casting plant

2 Form

2a Upper part of the form

2b Lower part of the form

3 Casting cavity

4 Cavity inlet

5 Feeding channels

6 Corps

6i Housing Inlet

6o Housing outlet

Channel 7

8 Upper surface of the form

9 Protective cover

9o Outlet of the protective casing

10 Protective casing shaft

11 Funnel

12 Pouring glass

13 Feeder bushing

14 Mold/Protection Cover Connection Mechanism

15 Installation element

16 Foundation element

17 Flexible element

17s Spiral spring

18 Levers

19 Centering pins

20 Central hole in the base element

21 Bushing

22 Filling

23 Performance

103 Bucket

105 Bucket base plate

106 Bayonet ring

107 Fastening hooks

109 Retaining pins

111 Hairpins

112 Inclined surfaces

113 Adhesive material

114 Support surface

115 Slanted edge

140f Funnel transition pipe

140n Pouring Cup Adapter

Claims (27)

1. A mould (2) for pouring molten metals, containing a casting cavity (3) having a casting cavity inlet (4), a housing (6) selected from a filter housing and a deflector housing, having an outlet opening (6o) of the housing made in fluid communication with an inlet opening (4) of the casting cavity, and an inlet opening (6i) of the housing made in fluid communication with a channel (7) passing between the upper surface (8) of the mold and the inlet opening (6i) of the housing, wherein said channel (7) is designed with the possibility of placing a protective casing (9) in it in the casting position, wherein the protective casing (9) comprises a funnel (11) mounted on the proximal end of the hollow shaft (10), and an outlet opening (9o) of the protective casing (9) on the distal end (10d) of the hollow shaft (10), wherein the position of the protective casing during casting is the placement of the hollow shaft (10) of the protective casing (9) in the channel (7) with the installation of its distal end (10d) through the inlet opening (6i) of the housing and placement of the outlet opening (9o) of the protective casing in the housing (6), wherein the inlet opening (6i) of the housing is designed with the possibility of communicating via a fluid medium with the outlet opening (9o) of the protective casing, a mechanism (14) for connecting the mold (2) and the protective casing (9), designed with the possibility of placing the protective casing (9) in the pouring position, characterized in that the mechanism (14) for connecting the mold and the protective casing comprises a base element (16) fixed on the upper surface (8) of the mold, an installation element (15) configured to receive a funnel (11) of the protective casing (9) and to install the protective casing (9) in the pouring position, wherein the installation element (15) is connected to the base element (16) by at least one flexible element (17) with the provision of separation of the installation element (15) from the base element (16), with the provision of the possibility of movement of the installation element (15) relative to the base element (16) when a load is applied to the installation element (15) and deformation of at least one flexible element (17), wherein said flexible element (17) comprises one or more elastic elements, including a spring passing between the installation element (15) and the base element (16). 2. The mould according to claim 1, characterized in that the base element (16) and the mounting element (15) each contain a central opening, made aligned with each other to ensure supply to the channel (7) of the protective casing (9), wherein the mechanism (14) for connecting the mould and the protective casing contains at least three elastic elements passing between the mounting element (15) and the base element (16), wherein said at least three elastic elements are preferably uniformly spaced from each other along the circumference of said central openings of the mounting element (15) and the base element (16). 3. A mold for pouring molten metals in an assembly, comprising a mold (2) according to claim 1 or 2, in the channel (7) of which a protective casing (9) is placed, wherein the funnel (11) of the protective casing (9) is placed in the mounting element (15), thus holding the protective casing (9) in the pouring position. 4. The mold according to item 3, characterized in that the protective casing (9) is fixed on the installation element (15) with filling (22) with molding sand, sealing the annular gap between the funnel (11) of the protective casing (9) and the installation element (15) and defining the installation location for the funnel (11). 5. A casting installation comprising a mould assembly according to one of paragraphs 3, 4 and a ladle (103) comprising a pouring nozzle (12) at the base of the ladle (103), ensuring the release of molten metal from the ladle (103), wherein the pouring nozzle (12) is designed with the possibility of reversible and sealing engagement with the funnel (11) of the protective casing (9), and wherein the ladle (103) is designed with the possibility of movement relative to the mould (2), ensuring: the arrangement of the pouring cup (12) essentially vertically above the mechanism (14) for connecting the mould and the protective casing, lowering vertically until the pouring cup (12) enters into sealing engagement with the funnel (11) of the protective casing (9) in the position of the protective casing (9) during pouring by applying a load to the installation element (15). 6. A casting installation according to claim 5, comprising a mechanism (140) for connecting a ladle and a protective casing, designed with the possibility of reversible gripping of the protective casing (9) by a pouring nozzle (12), preferably without forming a seal between the funnel (11) of the protective casing (9) and the pouring nozzle (12), wherein the mechanism (140) for connecting the ladle and the protective casing comprises: a transition pipe (140f) of the funnel, attached to the funnel (11) of the protective casing (9), wherein the transition pipe (140f) of the funnel comprises a retaining means, and a transition pipe (140n) of the pouring nozzle, fixed on the base of the ladle (103) or on the pouring nozzle (12) and designed with the possibility of engaging with the retaining means of the transition pipe (140f) of the funnel for reversible locking of the protective casing (9) on the pouring nozzle (12) in the locked position. 7. The casting installation according to claim 6, characterized in that the holding means of the transition pipe (140f) of the funnel comprises holding pins (109), while the transition pipe (140n) of the pouring nozzle comprises fastening hooks (107) designed with the possibility of reversible engagement of the holding pins (109) and, preferably, designed with the possibility of self-engagement with the holding pins (109). 8. A casting apparatus according to claim 6, characterized in that the retaining means of the transition pipe (140f) of the funnel comprises one or more retaining pins (109), and wherein the transition pipe (140n) of the pouring nozzle comprises a bayonet connection element designed with the possibility of interacting with one or more retaining pins (109) for reversible locking of the protective casing (9) on the pouring nozzle (12) in the locked position. 9. A casting installation according to any one of paragraphs 6-8, characterized in that the transition pipe (140f) of the funnel is fixed to the protective casing (9) using an adhesive material (113). 10. A casting installation according to any one of paragraphs 6-9, characterized in that the mounting element (15) comprises a conical part centered on the central opening of the mounting element, wherein the conical part is designed with the possibility of guiding the protective casing (9) for alignment with the channel (7) when lowering the ladle (103) vertically, wherein the protective casing (9) is reversibly locked on the pouring nozzle (12). 11. A method for pouring molten metal using a casting installation according to any of paragraphs 5-10, comprising: lowering the ladle (103) vertically until the load is applied by the pouring nozzle (12), which is engaged with the funnel (11) of the protective casing (9), to the funnel of the protective casing (9), mounted on the installation element (15), ensuring the movement of the installation element (15) relative to the element (16) of the base against the pliable elements (17) and the formation of a sealing contact between the pouring nozzle (12) and the protective casing (9), which is in the pouring position, ensuring the flow of molten metal from the ladle (103) into the casting cavity (3) through the pouring nozzle (12), protective casing (9) and body (6). 12. The method according to claim 11, characterized in that the protective casing (9) is fixed on the installation element (15) with filling (22) with molding sand, sealing the annular gap between the funnel (11) of the protective casing (9) and the installation element (15) and defining the installation location for the funnel (11), the pouring nozzle (12) is brought into engagement with the funnel (11) of the protective casing (9) by lowering the ladle (103) vertically with the formation of a sealing contact between the pouring nozzle (12) and the protective casing (9) by further lowering the ladle (103) to apply a load to the funnel (11) by the pouring nozzle (12). 13. The method according to item 11, characterized in that the engagement of the pouring nozzle (12) with the funnel (11) of the protective casing (9) and the engagement of the protective casing (9) with the pouring nozzle (12) are carried out by means of a mechanism (140) for connecting the ladle and the protective casing by engaging the retaining means of the transition pipe (140f) of the funnel, fixed on the funnel of the protective casing (9), by means of the transition pipe (140n) of the pouring nozzle, fixed on the base of the ladle (103) or on the pouring nozzle (12), for example, for locking the protective casing (9) on the pouring nozzle (12) in the locked position, the protective casing (9), locked onto the pouring cup (12), is positioned substantially vertically above the mechanism (14) for connecting the mould and the protective casing, lower the protective casing (9), locked on the pouring cup (12), vertically until the protective casing (9) reaches the pouring position with the funnel (11) resting on the installation element (15), form a sealing contact between the pouring cup (12) and the protective casing (9) by further lowering the ladle (103) with the pouring cup (12) to apply a load to the funnel (11) of the protective casing (9).