EP0430616A1 - Giessvorrichtung - Google Patents

Giessvorrichtung Download PDF

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Publication number
EP0430616A1
EP0430616A1 EP90312824A EP90312824A EP0430616A1 EP 0430616 A1 EP0430616 A1 EP 0430616A1 EP 90312824 A EP90312824 A EP 90312824A EP 90312824 A EP90312824 A EP 90312824A EP 0430616 A1 EP0430616 A1 EP 0430616A1
Authority
EP
European Patent Office
Prior art keywords
piston
die
speed
control
actuator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP90312824A
Other languages
English (en)
French (fr)
Inventor
Derek Lambert
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fernox Ltd
Original Assignee
Frys Metals Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Frys Metals Ltd filed Critical Frys Metals Ltd
Publication of EP0430616A1 publication Critical patent/EP0430616A1/de
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/02—Hot chamber machines, i.e. with heated press chamber in which metal is melted
    • B22D17/04—Plunger machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D18/00—Pressure casting; Vacuum casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/2015—Means for forcing the molten metal into the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details
    • B22D17/32—Controlling equipment

Definitions

  • This invention relates to casting apparatus and in particular but not exclusively to the casting of low melting point alloys for use in moulding plastics materials.
  • a microprocessor is in this arrangement provided for controlling the sequential operation of the actuator and its associated flow valve.
  • casting apparatus comprising a dispensing cylinder receiving molten metal in use, a piston slidably received in the cylinder, a rotary driven linear actuator operable to drive the piston in the cylinder, rotary drive means operable to drive the actuator and communicating means communicating during a dispensing stroke of the piston between the cylinder and a die for dispensing molten metal to the die, wherein the apparatus further comprises control means operable to control the rotational speed of the drive means to thereby control the speed of the piston and thereby control the rate at which molten metal is dispensed into the die.
  • the apparatus of the present invention thereby provides greater control and repeatability which is of particular importance in maintaining quality of casting.
  • control means is provided with data storage means receiving in use data defining a desired characteristic of piston speed as a function of time during the dispensing stroke and is operable to control the drive means such that the instantaneous speed of the piston is substantially equal to that of the desired characteristic during filling of the die.
  • piston speed can be varied during the dispensing stroke in a repeatable manner which can be tailored to suit the requirements of a particular die having a specific internal shape.
  • characteristic of piston speed it is possible to avoid imperfections in the resulting casting which are associated with the elevation speed at which the level of molten metal rises within the die.
  • characteristic of piston speed it is possible to maintain the elevation rate within preferred maximum and minimum values and to avoid turbulent effects associated with rapid change in elevation rate.
  • the drive means includes a rotary motor and slippable torque transmitting means transmitting rotary motion from the motor to the actuator whereby torque continues to be transmitted to the actuator after the piston is arrested by back pressure in the cylinder after the die is full.
  • the torque transmitting means comprises a clutch having means for adjusting the torque transmitted to thereby adjust the pressure of molten metal in the die when filled.
  • the clutch may be electromagnetically operated and adjustable by mechanical or electromechanical adjustment means.
  • the apparatus includes an actuator sensor responsive to the speed of rotation at which the linear actuator is driven, a motor sensor responsive to the speed of rotation of the motor and control means connected to the respective sensors and operable to control the speed of the motor.
  • the distance travelled by the actuator may therefore be controlled using a closed feedback loop in an accurate manner.
  • the torque transmitting means is adjustable by means actuated by the control means.
  • the torque limiting means is a clutch it may therefore be electromagnetically actuated by signals from the control means.
  • the rotary driven linear actuator comprises first and second cooperating screw threaded members, the drive means being operable to provide relative rotational movement between the first and second members resulting in relative linear motion by screw action and connecting means which connects the first and second members to the cylinder and piston respectively so as to provide actuating movement therebetween.
  • the first member is a screw threaded shaft and the second member is a cooperating nut which nut includes ball bearing means so that the nut and shaft together comprise a ball screw.
  • An advantage of using such a ball screw is that the screw action is accompanied by minimal frictional losses and minimal lost motion so that the piston position is accurately and smoothly controllable even at very slow actuation speeds.
  • a method of casting comprising the steps of placing a dispensing cylinder receiving molten metal in communication with a die and driving a piston in the cylinder by means of a rotary driven linear actuator such that molten metal is dispensed into the die during a dispensing stroke of the piston, and operating a control means to control the rotational speed of a rotary drive means driving the actuator to thereby control the rate at which molten metal is dispensed into the die.
  • the method includes the steps of operating the control means to control the speed of the drive means such that during filling of the die the piston speed is substantially equal to a desired characteristic of piston speed as a function of time.
  • the characteristic of piston speed against time is selected such that the level of molten metal in the die rises at an elevation rate which increases from zero to a minimum preferred value above which the elevation rate is thereafter maintained during the filling of the die.
  • the method may include the step of continuing to apply torque to the rotary driven linear actuator after the die has become filled with molten metal until the metal in the die has substantially solidified.
  • An advantage of this method is that any change of volume of the metal within the die can be compensated by an influx or efflux of molten alloy under pressure applied by the piston.
  • the method includes the step of varying the rotational speed at which the rotary driven linear actuator is driven during a time period in which the die is progressively filled with molten metal such that the level of molten metal within the die rises at a predetermined rate.
  • An advantage of this method is that the internal shape of the die can be taken account of in controlling the rate of influx of molten alloy in a manner which ensures that the die is completely filled without formation of surface defects.
  • Figure 1 is a partly sectioned elevation of casting apparatus
  • Figure 2 is a partly sectioned elevation of the actuator of the casting apparatus of Figure 1;
  • Figure 3 is a sectional elevation of a die for use with the casting apparatus of Figures 1 and 2;
  • Figure 4 is a graph of piston speed against time illustrating the characteristic of dispensed flow rate suitable for filling the die of Figure 3.
  • a casting apparatus 1 is suitable for casting metal alloys having low melting temperatures for example having solidus temperatures in the range of 35°C to 300°C.
  • the apparatus 1 has a tank 2 in which is held a quantity of molten alloy 3 which fills the tank to a normal level 4.
  • a cylinder 5 is located within the tank 2 and immersed in the molten alloy 3.
  • the cylinder 5 extends vertically upwardly from a mounting block 6 upon which it is supported and receives a piston 7 which is axially slidable within the cylinder.
  • the mounting block 6 rests upon supports 8 and 9.
  • the cylinder 5 defines a cylindrical dispensing chamber 10 and the mounting block 6 defines a conduit 11 communicating between the chamber and a three port ball valve 12.
  • the ball valve 12 has a ball 13 mounted on a stem 14 and located between valve seats 15 and 16 within a valve chamber 17 defined by the ball valve.
  • the valve 12 is provided with a first port 18 which communicates with the interior of the tank 2 so as to supply molten alloy to the valve, a second port 19 communicating with the conduit 11 so as to be in communication with the dispensing chamber 10 and a third port 20 communicating with a dispensing channel 21.
  • the stem 14 is axially movable by action of a ball valve actuator 22 such that the ball can be positioned to close either the first port 18 or the third port 20.
  • the dispensing channel 21 extends out of the tank 2 and communicates with a flow valve 23 which is actuated by a rotary flow valve actuator 24 to open or close the flow path through the flow valve.
  • a further portion 25 of the dispensing channel 21 communicates between the flow valve 23 and a die 26.
  • the dispensing channel 21 is formed in a fixed member 27 which is separable from the mounting block 6 such that the block can be removed from the tank.
  • the fixed member 27 includes a domed surface portion 28 locating in a corresponding recess 29 formed in the mounting block 6 for ease of alignment of the dispensing channel 21 with the third port 20 on refitting the mounting block 6 within the tank 2.
  • the tank 2 and the dispensing channel 21 are surrounded in insulating material 30 to maintain an even temperature throughout.
  • the piston 7 is driven by an actuating means 31 which is represented schematically in Figure 1 and is shown in detail in Figure 2.
  • the actuating means 31 includes a screw threaded shaft 32 on which is received a screw threaded nut 33 including ball bearing means (not shown) such that the shaft and nut together comprise a ball screw 34.
  • the screw threaded shaft 32 includes screw threads 35 of part circular cross-section adapted to cooperate with the ball bearing means of the nut 33.
  • the construction of the ball screw 34 is such that relative rotational movement between the nut 33 and the shaft 32 results in linear relative movement as in the case of known screw and nut combinations.
  • the nut 33 is rigidly connected to the piston 7 by means of a vertically extending tube 36 having a threaded coupling 37 at its lower end 38 allowing the piston to be bolted to the tube 36.
  • the screw threaded shaft 32 extends vertically and coaxially within the tube 36 and has an upper end 39 received in a bearing 40 which is connected to a tubular casing 41.
  • the casing 41 extends vertically with the tube 36 being coaxially received within the casing and the bearing 40 facilitates rotation of the shaft 32 relative to the casing but prevents longitudinal relative motion between the casing and the shaft 32.
  • a motor 42 has a driven shaft 43 arranged to drive an input pulley 44 of an adjustable clutch 45 via a toothed drive belt 46 and the clutch has an output shaft 47 rigidly connected in axial alignment with the screw threaded shaft 32.
  • the clutch 45 comprises a solenoid actuated disc clutch having means for adjusting the pressure applied between the discs (not shown) to thereby provide means for setting the maximum torque transmitted by the clutch.
  • a take-off pulley 48 is connected to the output shaft 47 of the clutch 45 and is connected by means of a toothed belt 49 to an actuator tachometer 50 for sensing actuator speed.
  • a motor tachometer 51 is connected to the motor 42 for sensing the motor speed.
  • a digital electronic control unit 52 is connected to receive output signals from the actuator tachometer 50 and the motor tachometer 51 indicating the rotational speeds of the screw threaded shaft 32 and the motor 42 respectively. As indicated schematically in Figure 1 the control unit 52 is connected to provide command signals to the motor 42 to regulate its speed, to the actuating solenoid of the clutch 45, to the ball valve actuator 22 to actuate the valve 12 and to the flow valve actuator 24 to control the actuation of the flow valve 23.
  • Upper and lower inductive proximity switches 53 and 54 respectively are connected to the casing 41 at vertically spaced apart locations and are arranged to sense the maximum and lower limits of normal travel of the nut 33 along the screw threaded shaft 32. Output signals from the proximity switches 53 and 54 are connected at inputs to the control unit 52.
  • the control unit 52 is provided with a memory 56 for receiving data defining the preferred characteristic of speed of piston 7 as a function of time during a dispensing stroke of the piston. The selection of the preferred characteristic is described below with reference to Figures 3 and 4.
  • the piston In use to dispense molten alloy 3 into the die 26 the piston is raised as shown in Figure 1 to its normal upper limit of travel with the chamber 10 filled with molten alloy.
  • the ball valve 12 is moved into a position in which the ball 13 is fully raised by actuation of the ball valve actuator 22 thereby closing the first port 18.
  • the ball valve 12 in this position provides communication between the conduit 11 and the dispensing channel 21.
  • the clutch 45 is set to provide a predetermined limit of torque such that torque across the clutch below a threshold limit will result in one-to-one transmission of drive through the clutch and torque exceeding the limit will result in slippage of the output shaft 47 relative to the speed at which the clutch is driven by the motor 42 whilst a set value of torque continues to be transmitted.
  • the motor 42 is then driven at an initial speed under the control of the control unit 52 such that the clutch 45 is driven by the drive belt 46, the output shaft 47 of the clutch being correspondingly driven to thereby drive the screw threaded shaft 32 at an initial rate of rotation.
  • Rotation of the shaft 32 results in linear movement of the nut 33 relative to the shaft, the direction of rotation of the motor being selected to be such that the nut moves downwards relative to the shaft.
  • the nut 33 is rigidly connected to the piston 7 the piston moves correspondingly downwards and displaces molten alloy from the chamber 10. Alloy flows from the chamber 10 through the conduit 11, through the valve 12 into the dispensing channel 21, through the flow valve 23, through the further portion 25 of the dispensing channel 21 and into the die 26. Throughout this flow path the insulation 30 retains the molten alloy at a temperature above its solidus temperature.
  • the rate at which alloy is dispensed and the precise volume which has been displaced is monitored by the control unit 52 by means of signals received from the actuator tachometer 50 which provides a signal directly proportional to the rotational speed of the shaft 32, the travel of the piston being calculated by integrating the signal.
  • the control unit 52 adjusts the speed of the motor 42 during the dispensing operation in order to achieve a predetermined characteristic of piston speed against time. Since the actual displacement of the piston 7 is measured by the control unit and the speed of the piston directly regulated by the control unit this constitutes a closed loop feedback system providing precise control of the dispensing operation.
  • the incompressibility of the liquid alloy 3 arrests the motion of the piston 7 such that the torque experienced across the clutch 45 exceeds the threshold limit to which it is set and the clutch therefore begins to slip.
  • the halting of the piston 7 is sensed by the control unit 52 which then sets the motor 42 to run at a speed which maintains a set level of torque across the clutch 45 so as to bias the piston 7 downwardly and maintain a constant level of pressure in the dispensing flow path.
  • the metal alloy within the die 26 is allowed to cool and solidify and in doing so undergoes a change of volume, either an increase or decrease, depending on the composition of the alloy. A decrease in volume will be accompanied by a slight influx of molten alloy to the die and the piston will move down accordingly by a small amount.
  • control unit actuates the flow valve actuator 24 to turn off the flow valve 23 and the die 26 is removed from the casting apparatus 1 and replaced with the same die after removal of the solidified casting or with a further empty die.
  • the control unit 52 then actuates the ball valve actuator to lower the ball 13 so as to close the third port 20 and open the first port 18.
  • the direction of rotation of the motor 42 is reversed and the piston 7 is then raised to create suction within the chamber 10 and draw molten alloy 3 from the tank 2 which constitutes a reservoir.
  • the dispensing operation can then be repeated as described above after first opening the valve 23.
  • the piston 7 may be raised and lowered with the ball valve in its fully lowered position such that molten alloy from the tank 2 is cyclically drawn into and expelled from the chamber 10 in order to ensure that adequate agitation of the alloy is maintained to prevent dissociation of its constituent metals.
  • the upper and lower proximity switches 53 and 54 provide inputs to the control unit 52 as to when the piston has reached its operating limits of travel.
  • Figures 3 and 4 illustrate the manner in which the movement of piston 7 is controlled in order to tailor the characteristic of piston speed against time to suit a particular application.
  • an alternative die 60 defines a cavity 61 having a shape resembling that of an inverted bottle.
  • the shape of cavity 61 is symmetrical about a vertical axis and includes a cylindrical upper portion 62 of uniform cross-section.
  • a lower portion 63 of cavity 61 has a reduced cross-section and is connected to the cylindrical upper portion 62 by a flared portion 64 which merges smoothly and continuously with the upper and lower portions 61 and 62 respectively.
  • the die 60 is filled through an inlet 65 communicating with the lower portion 63 and is connected in use with the nozzle 55 of the apparatus of Figures 1 and 2.
  • Figure 4 illustrates graphically the preferred characteristic of speed S of piston 7 as a function of time t during a dispensing operation in which molten alloy is dispensed from the cylinder 5 into the cavity 61.
  • the piston begins to move smoothly and with gradually increasing speed from its rest position and the flow rate of molten alloy into the cavity 61 increases in direct proportion to this speed S.
  • This gradual pick-up in flow rate ensures that the rising level of molten alloy remains substantially free from turbulence without the formation of jets.
  • the elevation rate at which the level of molten alloy within the cavity 61 is rising will have reached a preferred minimum value above which the elevation rate is to be maintained during the filling of the cavity. If the level rises at a slower rate then surface imperfections in the casting result from the tendency to freezing of the meniscus formed at the interface between the alloy surface and the walls of the die 60. The flow of metal over the frozen meniscus results in unwanted lines being formed on the resulting casting.
  • the speed S of the piston 7 is controlled such that the alloy level rises at an elevation rate which is greater than or equal to the preferred minimum elevation rate and which is not greater than a preferred maximum elevation rate depending upon the particular shape of the cavity 61. If the elevation rate is too high then excessive pressures within the die result at the end of period C when the die becomes entirely filled and this can result in unwanted flashes being formed on joint faces of the die. When filling more complex die cavities there is an additional hazard in filling too quickly in that unwanted voids can result in the casting due to entrapment of air.
  • the preferred characteristic of S as a function of t for a given die may be arrived at empirically with the speed characteristic being adjusted to remove surface imperfections or voids found in castings resulting from trial dispensing operations. Once a satisfactory casting has been produced from a given speed characteristic it has been found that subsequent castings using the same speed characteristic show a high degree of reproducability with consequent high yields of high quality castings.
  • the characteristic of S as a function of t may also be arrived at for new die shapes by theoretical calculation based on empirical values obtained from dies of simple shape. Such calculations may conveniently be expressed as algorithms processed in a computer in which information concerning the shape of the die cavity is entered directly from computer aided design data.
  • the memory 56 may comprise an electrically erasable programmable read-only memory or alternatively may comprise other known data storage means.
  • the apparatus and method of the present invention may be used with a cylinder and piston of different diameter and capacity where appropriate for dies of different volume so that it will be necessary to input to the control means the relevant parameters of piston and cylinder currently in use.
  • the torque transmitting means may alternatively be a magnetic clutch.
  • the piston speed may be regulated without including the step of sensing the halting of the piston 7 by the control unit 52.
  • the motor may instead be set to run at a reduced speed which maintains a constant level of pressure in the filled die under the control of the control unit 52 after a predetermined time interval equal to the time taken to fill the die.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
EP90312824A 1989-11-30 1990-11-26 Giessvorrichtung Withdrawn EP0430616A1 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB898927088A GB8927088D0 (en) 1989-11-30 1989-11-30 Casting apparatus
GB8927088 1989-11-30

Publications (1)

Publication Number Publication Date
EP0430616A1 true EP0430616A1 (de) 1991-06-05

Family

ID=10667199

Family Applications (1)

Application Number Title Priority Date Filing Date
EP90312824A Withdrawn EP0430616A1 (de) 1989-11-30 1990-11-26 Giessvorrichtung

Country Status (8)

Country Link
EP (1) EP0430616A1 (de)
JP (1) JPH03268854A (de)
KR (1) KR910009367A (de)
AU (1) AU625361B2 (de)
BR (1) BR9006064A (de)
CA (1) CA2030761A1 (de)
GB (2) GB8927088D0 (de)
ZA (1) ZA909470B (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4310310A1 (de) * 1993-03-30 1994-10-06 Frech Oskar Gmbh & Co Einpreßaggregat
EP0711616A3 (de) * 1994-11-15 1997-05-07 Bachmann Giesserei & Formen Vorrichtung zum Giessen von Metallen
US6581670B1 (en) 1999-06-01 2003-06-24 Oskar Frech Gmbh & Co. Injection unit for a pressure die casting machine

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2300231A (en) * 1995-03-31 1996-10-30 Trimcote Ltd Fluid dispenser
JPH10272550A (ja) * 1997-03-31 1998-10-13 Ryobi Ltd 溶湯給湯方法及び溶湯給湯装置
CN117564258B (zh) * 2024-01-16 2024-03-29 卡耐夫集团(山西)管道***有限公司 一种管件生产用浇铸设备及使用方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB420728A (en) * 1932-12-10 1934-12-06 Franz Braun Ag Improvements in and relating to injection moulding machines for plastic materials
DE644695C (de) * 1932-12-11 1937-05-11 Franz Braun Akt Ges Spritzgussmaschine fuer plastische Massen
FR1396544A (fr) * 1964-03-13 1965-04-23 Presse pour le moulage par injection de matières plastiques
EP0177257A2 (de) * 1984-10-05 1986-04-09 Fry's Metals Limited Giessmaschine

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS61220817A (ja) * 1985-03-28 1986-10-01 Fanuc Ltd 射出成形機の計量混練方式
JPH0722813B2 (ja) * 1989-01-30 1995-03-15 宇部興産株式会社 射出装置

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB420728A (en) * 1932-12-10 1934-12-06 Franz Braun Ag Improvements in and relating to injection moulding machines for plastic materials
DE644695C (de) * 1932-12-11 1937-05-11 Franz Braun Akt Ges Spritzgussmaschine fuer plastische Massen
FR1396544A (fr) * 1964-03-13 1965-04-23 Presse pour le moulage par injection de matières plastiques
EP0177257A2 (de) * 1984-10-05 1986-04-09 Fry's Metals Limited Giessmaschine

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN, vol. 10, no. 73 (M-463)[2130], 22nd March 1986; & JP-A-60 216 964 (UBE KOSAN K.K.) 30-10-1985 *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4310310A1 (de) * 1993-03-30 1994-10-06 Frech Oskar Gmbh & Co Einpreßaggregat
US5482101A (en) * 1993-03-30 1996-01-09 Oskar Frech Gmbh & Co. Pressing-in device
EP0711616A3 (de) * 1994-11-15 1997-05-07 Bachmann Giesserei & Formen Vorrichtung zum Giessen von Metallen
US6581670B1 (en) 1999-06-01 2003-06-24 Oskar Frech Gmbh & Co. Injection unit for a pressure die casting machine

Also Published As

Publication number Publication date
GB8927088D0 (en) 1990-01-31
AU625361B2 (en) 1992-07-09
KR910009367A (ko) 1991-06-28
CA2030761A1 (en) 1991-05-31
JPH03268854A (ja) 1991-11-29
GB9025955D0 (en) 1991-01-16
ZA909470B (en) 1991-08-28
BR9006064A (pt) 1991-09-24
GB2238497B (en) 1993-04-07
GB2238497A (en) 1991-06-05
AU6679290A (en) 1991-06-06

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