This invention related to an apparatus for feeding moulding material
towards a moulding station where the moulding material may be used in a
moulding apparatus.
The invention has particularly but not exclusively been devised for use
in feeding moulding material comprising metal powder, and usually a lubricant,
from a convenient position towards a metal powder moulding apparatus where the
powder is formed to a shape in a mould (known as a die) as pressure is applied.
However the invention may be utilised in other applications where it is desired to
feed appropriate alternative moulding material towards a moulding station.
Various proposals have been made for such apparatus for feeding metal
powder towards a moulding station, including a proposal for achieving conveying
of the material by means of an auger being a usually helically arranged member
with a central core, about which a continuous heating tape is entrained, so that the
metal powder can be kept in a warm state as it is conveyed. Using an auger has an
advantage in that the metal powder and lubricant constituents are continually mixed
as they are conveyed, but the arrangement proposed previously has suffered from
several problems.
First, the use of a continuous tape type of heater, means that it is
difficult to control the temperature of the powder being conveyed, along the whole
length of the auger.
Second, the auger tends to compress the powder with the result that the
auger tends to become clogged with compressed material, making it less effective
for conveying and eventually resulting in failure of the feeding apparatus.
The metal powder is conventionally fed into a receptacle, such as a
funnel from where it is conveyed towards the moulding station, and at or adjacent
the moulding station, conventionally there is a reservoir for the moulding material
from which moulding material is taken into a moulding apparatus for moulding.
Usually, heating tape is entrained about the funnel and the reservoir but this does
not result in heat being properly applied to the metal powder etc.
Unless the temperature of the metal powder is properly controlled,
during feeding and in the receptacle and the reservoir, the quality of the resultant
moulding may be effected, and the moulding apparatus can become worn
prematurely, particularly where the metal powder is a ferrous or other hard, based
metal.
According to a first aspect of the invention we provide an apparatus for
feeding moulding material towards a moulding station, the feeding apparatus
comprising a receptacle for the moulding material at a first location, conveyor
means for conveying moulding material from the receptacle towards a second
location, reservoir means at the second location, the second location being at or
adjacent the moulding station, heating means for heating the moulding material as
it is conveyed by the conveying means characterised in that the heating means
comprises a plurality of heating units spaced along the conveyor means, and a
control means individually to control the heat output of the plurality of heating
units thereby to provide zonal heating control along the conveyor means.
Thus, more accurate control of the temperature of the moulding
material as it is conveyed may be achieved than with hithertofore known apparatus.
The conveyor means may comprises a rotatable screw member received
in a casing, the rotatable screw member having a generally central hollow. For
example the hollow rotatable screw member may comprise a helical wire but any
other suitable hollow screw member may instead be provided.
In each case the hollow screw member may in use rotated by a motive
means through a transmission including a continuous loop element such as a
toothed belt
Thus in such an apparatus the advantages of using an auger type feed
are preserved, but the problem of compaction of the moulding material has been
overcome or at least lessened.
The receptacle may comprise an open top through which moulding
material is introduced into the receptacle and may include a heating means for
heating the moulding material therein, the heating means comprising at least one
heating element which extends through the receptacle and is in use at least partly
embedded in the moulding material.
It has been found that by providing such a heating means for the
receptacle, particularly in a metal powder moulding process, the temperature of the
moulding material can be maintained more even than with known heating tape and
the like arrangements.
The receptacle may have at least one tube extending therethrough in
which the heating element is located in use.
The apparatus of the invention may also comprise a heating means for
heating the moulding material in the reservoir means, the heating means comprising
at least one heating unit which extends only partly about an exterior wall of the
reservoir means.
Thus using a heating means of this kind, such as a band heater, for the
reservoir of moulding material, again more accurate control of the temperature of
the moulding material in the reservoir means may be achieved.
Each of the heating means of the receptacle, the conveyor means and
the reservoir means may be controlled by a control means in response to inputs
from various sensor means which sense the temperature of the moulding material
(directly or indirectly).
The invention is particularly but not exclusively applicable where the
moulding material comprises metal powder and a lubricant, but may be used in
other applications.
The invention will now described with reference to the accompanying
drawings which is an illustrative perspective view of an apparatus in accordance
with the invention.
Referring to the drawing there is shown an apparatus 10 for feeding
moulding material towards a moulding station at a second location 13. The
apparatus 10 comprises a generally funnel shaped receptacle 11 for the moulding
material at a first location, a conveyor means 12 for conveying moulding material
from the receptacle 11 towards the second location 13, a reservoir means 14 at the
second location 13. The apparatus 10 is particularly for feeding moulding material
comprising metal powder which preferably contains a lubricant, which is moulded
at the moulding station by a powder moulding technique under pressure, or
compaction in a mould or die, to form the metal powder into a desired
configuration.
The receptacle 11 has an open top 15 into which moulding material
may be introduced at a convenient location distant from the moulding station.
Within the receptacle 11, there is provided a heating means for heating the
moulding material in the receptacle 11, the heating means comprising at least one
heating element 19 which extends through the receptacle 11, in this example there
being several heating elements each located in a respective tube 17, at least some of
the tubes 17 being embedded in the moulding material in the receptacle 11 in use.
The temperature of the moulding material in the receptacle 11 is
carefully controlled by a control means 20 which receives an input from an
appropriate sensor 18 which is also in use embedded in the moulding material in
the receptacle 11. The sensor 18 sends a signal along a line 21 to the control means
20. Depending on the temperature sensed, the control means 20 sends appropriate
control signals along a control line 22 to the heating elements 19 within the tubes
17. If desired, all of the heating elements 19 may be controlled in parallel, or at
least some of the heating elements 19 may be controlled individually, so that heat
of varying intensity may be imparted into the moulding material within the
receptacle 11 as it waits to be conveyed along the conveyor means 12.
The conveyor means 12 comprises an outer casing 25 and an inner
casing 26. Within the inner casing 26 there is provided a rotatable screw member
27 having a generally central hollow, and which in this example comprises a
helical wire, the diameter of the screw member 27 being slightly less than the
inside diameter of the inner casing 26 of the conveyor means 12.
In use, the hollow screw member 27 is rotated by means of a motive
means 28 comprising in this example an electric motor, which drives the hollow
rotatable screw member 27 via a transmission, which includes in this example, a
toothed belt 29 although any other flexible loop may be utilised, or indeed any
other appropriate direct or indirect transmission may be used as desired.
The hollow screw member 27 in the form of a helical wire, acts in the
manner of an auger to convey the moulding material from the receptacle 11, or at
least a base 11a of the receptacle 11 along the casing 26 from the first receptacle 11
towards the second location 13. By virtue of the screw member 27 being hollow, it
has been found that the metal powder tends not to be compacted within the casing
26 but is more easily carried along the conveyor means 12 without problems
occurring.
As the metal powder and lubricant is conveyed, hotter and colder
volumes are mixed so that a more even temperature throughout the powder volume
is achieved. Further, to preserve the temperature of the moulding material as it is
conveyed, according to the invention, the temperature is controlled zonally along
the conveying means 12. This is achieved by the provision of a plurality of heating
units 30, only two of which are illustrated in the example, each heating unit 30
being for example, a band heater and having an associated heat sensor 31. The
sensors 31 provide signals along appropriate lines 32 to the control means 20,
which in response, controls operation of the heating units 30 to switch them on or
off or otherwise to control the heat dissipated by the heating units 30 in their zonal
positions.
In this way the temperature of the moulding material as it is conveyed
along conveyor 12 can be maintained within quite strict limits.
At the second location 13 there is provided a receptacle 14 for receiving
the mixed conveyed moulding material and for holding the mixed moulding
material until it is carried into a moulding apparatus, for example by means of a
shuttle 35, where it is moulded, i.e. compacted in a mould or die under pressure.
To control the temperature of the moulding material in the reservoir 14
there is provided a heating means comprising a band heater 36 which extends only
partly around the reservoir 14 but in intimate contact with the outside surface of the
reservoir 14. The effect of this heating means 36 is monitored by means of a
sensor 37 which provides an input to the control means 20 along line 38, and in
response, the control means 20 controls the heating means 36 so that the
temperature of the moulding material within the reservoir 14 is maintained
substantially constant. More than one band heater 36 may be provided if desired.
In the arrangement shown, the reservoir 14 is deep and hence a second
heating means is provided comprising a second heating element and sensor 36a,37a
which are also connected to the control means 20.
The reservoir 14 also is provided with a level sensor 39 which senses
the level of metal powder in the reservoir 14. When the level rises to sensor 39,
sensor 39 provides an input (or stops providing an input) to control means 20
along line 40. In response, control means 20 may slow the speed of the screw
member 27, or may stop the screw member 24 rotating altogether, until the level of
metal powder in the reservoir 14 again falls below the level of the sensor 39 (or a
second, lower, sensor; not shown).
Then the screw member 27 may again be rotated, or rotated at full
speed, to deliver more metal powder to the reservoir 14. Mainly by virtue of the
zonal temperature control along the conveyor 12, this does not present any problem
of the powder and lubricant being too hot or cold in the conveyor 12.
Various modifications may be made without departing from the scope
of the invention.
For example, the particular nature of the receptacle 11 may be varied.
The receptacle 11 shown is generally funnel shaped, but could be of an alternative
configuration although preferably has an open top 15 to receive the moulding
material.
The length of the conveyor means 12 between the receptacle 11 and the
second location 13 may be varied substantially from what is shown although the
gauge of the wire for the hollow screw member 27 may need to be increased over
particularly long runs of conveyor means 12 or even some mechanism by which
drive is imparted to an opposite end 38 of the hollow screw member 27 to that at
which the motive means 28 is provided, may need to be provided.
It is preferred for a space between the outer 25 and inner 26 casings of
the conveyor means 12 to be insulated to preserve heat within the inner casing 26
although the outer casing 25 may in some applications be omitted altogether.
The nature of the reservoir 14 is dependant largely upon the moulding
apparatus adjacent thereto. In the example described, the reservoir 14 forms part of
the moulding apparatus although may be a more simple reservoir from which
moulding material is removed and delivered directly into the moulding apparatus.
Although the invention has been described with reference to a moulding
apparatus for moulding metal powder, the principles of the invention may be
applied to other kinds of moulding apparatus.
The features disclosed in the foregoing description the following claims
or the accompanying drawings, expressed in their specific forms or in terms of a
means for performing the disclosed function, or a method of process for attaining
the disclosed result, or a class or group of substances or compositions, as
appropriate, may, separately, or in any combination of such features, be utilised for
realising the invention in diverse forms thereof.