EP4316689A1 - Control system for the solidification process in large-size castings and process control of solidification in large-size castings - Google Patents
Control system for the solidification process in large-size castings and process control of solidification in large-size castings Download PDFInfo
- Publication number
- EP4316689A1 EP4316689A1 EP22205687.1A EP22205687A EP4316689A1 EP 4316689 A1 EP4316689 A1 EP 4316689A1 EP 22205687 A EP22205687 A EP 22205687A EP 4316689 A1 EP4316689 A1 EP 4316689A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- casting
- water
- proportional
- flow regulator
- solidification process
- 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.)
- Pending
Links
- 238000005266 casting Methods 0.000 title claims abstract description 42
- 238000000034 method Methods 0.000 title claims abstract description 29
- 238000007711 solidification Methods 0.000 title claims abstract description 21
- 230000008023 solidification Effects 0.000 title claims abstract description 21
- 238000004886 process control Methods 0.000 title claims abstract description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 35
- 239000002826 coolant Substances 0.000 claims abstract description 21
- 238000001816 cooling Methods 0.000 claims abstract description 21
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 9
- 239000010959 steel Substances 0.000 claims abstract description 9
- 239000003595 mist Substances 0.000 claims description 6
- 238000000605 extraction Methods 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 3
- 239000012467 final product Substances 0.000 description 2
- 229910001338 liquidmetal Inorganic materials 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/065—Cooling or heating equipment for moulds
Definitions
- the object of the invention is a system for controlling the solidification process in large-sized castings, and a method for controlling the solidification process in large-sized castings.
- volumetric chills for cooling castings are known from common usage. They are usually metal inserts with thermal conductivity several times higher than the conductivity of the moulding sand, placed in the mould cavity or near the surface of the casting, which allow for local control of solidification.
- the first chill type is an internal chill, made of the same material as the casting, which is placed in the space filled by the metal, and its function is to melt into the casting.
- the second chill type constitutes a part of the mould cavity surface, matching the part of the casting which is being cooled down.
- the determining factors for the rate and the amount of heat extraction from a casting undergoing solidification by an external chill are the type of material of which it is made, its heat capacity, and the thermal conductivity coefficient.
- a characteristic phenomenon during the use of external chills is the extraction of heat from the chill placement zone in the first step of the solidification process, until reaching an equilibrium of the temperatures of the cooling casting and the chill. Once the temperatures reach an equilibrium, the cooling rate of the casting in the chill placement zone drops drastically, and most importantly and also undesirably, a so-called local thermal node is created, indirectly affecting the microstructure of the casting.
- the purpose of the present invention is to provide a stable process for cooling large-sized castings, the ability to precisely control this process, and to improve the microstructure of a casting undergoing solidification, as well as the geometrical, dimensional, utilitarian and qualitative properties of the final product.
- the system consists of active cooling segments placed inside a casting mould, made of at least two steel plates with a shape matching the casting and known heat capacity, permanently connected to a tube coil, whose inlet and outlet nozzles extend outside the mould.
- the inlet nozzle is connected by a flexible hose with a proper cross-section to a compressed air supply module, provided with a supply collector connected to a pneumatic network, a proportional air flow regulator, and an injector, which is connected to a proportional water flow regulator, connected to the water mains.
- the outlet nozzle is provided with a cooling medium temperature sensor.
- the proportional air flow regulator, the proportional water flow regulator, and the cooling medium temperature sensor are connected to an automatic solidification process control console.
- the essence of the solution with respect to the second invention is in that inside the casting mould there are mounted active cooling segments, made of at least two steel plates with a shape matching the casting and known heat capacity, permanently connected to a tube coil whose inlet and outlet nozzles extend outside the mould.
- active cooling segments made of at least two steel plates with a shape matching the casting and known heat capacity, permanently connected to a tube coil whose inlet and outlet nozzles extend outside the mould.
- compressed air is introduced into the tube coils, upon which its temperature is controlled in a continuous manner, and upon reaching an air temperature of 105°C, water is introduced into the system and mixed with compressed air, generating water mist which constitutes a cooling medium.
- the pressure and flow of the coolant as well as the degree of saturation of air with water are controlled and adjusted, thus changing the intensity of heat extraction from the steel plates.
- the casting solidification process is controlled by means of a control console provided with an algorithm.
- the air flow rate has a value ranging from 300 to 1000 l/min.
- the degree of saturation of the cooling mixture with water mist is no higher than 5% in a volume ratio.
- the advantage of the solution according to the invention is the ability to provide a stable process for cooling large-sized castings, to precisely control this process, and to improve the microstructure of a casting undergoing solidification, as well as the geometrical, dimensional, utilitarian and qualitative properties of the final product.
- Using a water and air mixture in a temperature above 105°C ensures increasing the performance of the system of tube coils, as well as the safety of the process by fast evaporation of water and evacuation of water vapour generated in this manner, which prevents the phenomenon of condensation and local concentration of water in the liquid state.
- Fig. 1 presents a layout of a complete automated system for controlling the solidification process of a large-sized casting
- Fig. 2 - a single cooling segment
- Fig. 3 - a block diagram illustrating the operating principle of the system.
- active cooling segments 2 made of at least two steel plates 3, with a shape matching the casting and known heat capacity, permanently connected to a tube coil 4, whose inlet 13 and outlet 14 nozzles extend outside the casting mould 1.
- the inlet nozzle 13 of the active cooling segment 2 is connected by a flexible hose 5 with a proper cross-section to a compressed air supply module 6.
- the compressed air supply module 6 is made of a supply collector 7, a proportional air flow regulator 8, and an injector 9.
- the injector 9 is connected to a proportional water flow regulator 10, connected to the water mains.
- At the outlet of the cooling segment there is a cooling medium temperature sensor 11.
- the proportional air flow regulator 8, the proportional water flow regulator 10, and the cooling medium temperature sensor 11 are connected to an automatic solidification process control console 12.
- the supply collector 7 is connected to a pneumatic network.
- the first step of the process is to fill the casting mould 1 with liquid metal.
- an automatic cycle is activated by means of the control console 12, provided with an algorithm controlling the course of solidification.
- a control signal is transmitted to the proportional compressed air flow regulators 8, in order to open them and ensure the flow of air through the system of tube coils 4.
- the values of air temperatures at the outlet of the system of tube coils of the active cooling segments 2 are recorded and controlled in a continuous manner.
- a signal is transmitted to the proportional water flow regulators 10, opening the flow of water towards the injector 9.
- air is mixed with water, resulting in the generation of water mist, which is a cooling medium, considerably increasing the performance and efficiency of extracting heat from the steel plates, the degree of saturation of the cooling mixture with water mist being no higher than 5% in a volume ratio.
- the values of coolant temperatures at the outlet of the system of tube coils are still recorded and controlled in a continuous manner, with simultaneous smooth control of the proportional air 8 and water flow 10 regulators; the pressure and flow of the coolant through the system of tube coils 4 and the degree of saturation of air with water are adjusted, thus changing the intensity of heat extraction from the chills 3, which directly translates into the cooling rate of the casting.
- the air flow rate has a value ranging from 300 to 1000 l/min.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Continuous Casting (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
The object of the invention is a system for controlling the solidification process in large-sized castings, and a method for controlling the solidification process in large-sized castings, characterised in that it consists of any number of active cooling segments made of at least two steel plates with a shape matching the casting and known heat capacity, permanently connected to a tube coil (4), whose inlet (13) and outlet (14) nozzles extend outside the casting mould, the inlet nozzle being connected by a flexible hose (5) with a proper cross-section to a compressed air supply module (6), provided with a supply collector (7) connected to a pneumatic network, a proportional air flow regulator (8), and an injector (9), which is connected to a proportional water flow regulator (10), connected to the water mains, while the outlet nozzle is provided with a cooling medium temperature sensor (11), and the proportional air flow regulator, the proportional water flow regulator, and the cooling medium temperature sensor are connected to an automatic solidification process control console (12).
Description
- The object of the invention is a system for controlling the solidification process in large-sized castings, and a method for controlling the solidification process in large-sized castings.
- Volumetric chills for cooling castings are known from common usage. They are usually metal inserts with thermal conductivity several times higher than the conductivity of the moulding sand, placed in the mould cavity or near the surface of the casting, which allow for local control of solidification. The first chill type is an internal chill, made of the same material as the casting, which is placed in the space filled by the metal, and its function is to melt into the casting. The second chill type constitutes a part of the mould cavity surface, matching the part of the casting which is being cooled down. The determining factors for the rate and the amount of heat extraction from a casting undergoing solidification by an external chill are the type of material of which it is made, its heat capacity, and the thermal conductivity coefficient.
- A characteristic phenomenon during the use of external chills is the extraction of heat from the chill placement zone in the first step of the solidification process, until reaching an equilibrium of the temperatures of the cooling casting and the chill. Once the temperatures reach an equilibrium, the cooling rate of the casting in the chill placement zone drops drastically, and most importantly and also undesirably, a so-called local thermal node is created, indirectly affecting the microstructure of the casting.
- The purpose of the present invention is to provide a stable process for cooling large-sized castings, the ability to precisely control this process, and to improve the microstructure of a casting undergoing solidification, as well as the geometrical, dimensional, utilitarian and qualitative properties of the final product.
- The essence of the solution with respect to the first invention is in that the system consists of active cooling segments placed inside a casting mould, made of at least two steel plates with a shape matching the casting and known heat capacity, permanently connected to a tube coil, whose inlet and outlet nozzles extend outside the mould. The inlet nozzle is connected by a flexible hose with a proper cross-section to a compressed air supply module, provided with a supply collector connected to a pneumatic network, a proportional air flow regulator, and an injector, which is connected to a proportional water flow regulator, connected to the water mains. The outlet nozzle is provided with a cooling medium temperature sensor. The proportional air flow regulator, the proportional water flow regulator, and the cooling medium temperature sensor are connected to an automatic solidification process control console.
- The essence of the solution with respect to the second invention is in that inside the casting mould there are mounted active cooling segments, made of at least two steel plates with a shape matching the casting and known heat capacity, permanently connected to a tube coil
whose inlet and outlet nozzles extend outside the mould. Upon filling the casting mould with liquid metal, compressed air is introduced into the tube coils, upon which its temperature is controlled in a continuous manner, and upon reaching an air temperature of 105°C, water is introduced into the system and mixed with compressed air, generating water mist which constitutes a cooling medium. In the further course of the process, the pressure and flow of the coolant as well as the degree of saturation of air with water are controlled and adjusted, thus changing the intensity of heat extraction from the steel plates. When the temperature of the cooling medium drops below 105°C, the inflow of water is closed, and the cooling process ends when the coolant temperature drops below 80°C. Preferably, the casting solidification process is controlled by means of a control console provided with an algorithm.
Preferably, the air flow rate has a value ranging from 300 to 1000 l/min. Preferably, the degree of saturation of the cooling mixture with water mist is no higher than 5% in a volume ratio. - The advantage of the solution according to the invention is the ability to provide a stable process for cooling large-sized castings, to precisely control this process, and to improve the microstructure of a casting undergoing solidification, as well as the geometrical, dimensional, utilitarian and qualitative properties of the final product. Using a water and air mixture in a temperature above 105°C ensures increasing the performance of the system of tube coils, as well as the safety of the process by fast evaporation of water and evacuation of water vapour generated in this manner, which prevents the phenomenon of condensation and local concentration of water in the liquid state.
- The solution according to the invention with respect to the system is presented in the drawing, where
Fig. 1 presents a layout of a complete automated system for controlling the solidification process of a large-sized casting,Fig. 2 - a single cooling segment,Fig. 3 - a block diagram illustrating the operating principle of the system. - Inside the
casting mould 1, there are mountedactive cooling segments 2 made of at least twosteel plates 3, with a shape matching the casting and known heat capacity, permanently connected to atube coil 4, whoseinlet 13 and outlet 14 nozzles extend outside thecasting mould 1. Theinlet nozzle 13 of theactive cooling segment 2 is connected by aflexible hose 5 with a proper cross-section to a compressedair supply module 6. The compressedair supply module 6 is made of asupply collector 7, a proportionalair flow regulator 8, and aninjector 9. In addition, theinjector 9 is connected to a proportionalwater flow regulator 10, connected to the water mains. At the outlet of the cooling segment there is a coolingmedium temperature sensor 11. The proportionalair flow regulator 8, the proportionalwater flow regulator 10, and the coolingmedium temperature sensor 11 are connected to an automatic solidificationprocess control console 12. Thesupply collector 7 is connected to a pneumatic network. - The first step of the process is to fill the
casting mould 1 with liquid metal. Upon finishing the filling process, an automatic cycle is activated by means of thecontrol console 12, provided with an algorithm controlling the course of solidification. By means of thecontrol console 12, a control signal is transmitted to the proportional compressedair flow regulators 8, in order to open them and ensure the flow of air through the system oftube coils 4. The values of air temperatures at the outlet of the system of tube coils of theactive cooling segments 2 are recorded and controlled in a continuous manner. Upon reaching a temperature of approx. 105°C at the outlet of the tube coil system, a signal is transmitted to the proportionalwater flow regulators 10, opening the flow of water towards theinjector 9. In theinjector 9, air is mixed with water, resulting in the generation of water mist, which is a cooling medium, considerably increasing the performance and efficiency of extracting heat from the steel plates, the degree of saturation of the cooling mixture with water mist being no higher than 5% in a volume ratio. The values of coolant temperatures at the outlet of the system of tube coils are still recorded and controlled in a continuous manner, with simultaneous smooth control of theproportional air 8 andwater flow 10 regulators; the pressure and flow of the coolant through the system oftube coils 4 and the degree of saturation of air with water are adjusted, thus changing the intensity of heat extraction from thechills 3, which directly translates into the cooling rate of the casting. The air flow rate has a value ranging from 300 to 1000 l/min. In the final step of the process, when the temperature of the cooling medium at the outlet of the system of tube coils drops below 105° C, a signal is transmitted from thecontrol console 12 to the proportionalwater flow regulators 10, and the inflow of water to theinjector 9 is closed. The process ends when the temperature of the coolant drops below 80°C.
Claims (5)
- A system for controlling the solidification process in large-sized castings, comprising chills placed inside a casting mould (1), characterised in that it consists of any number of active cooling segments (2) made of at least two steel plates (3) with a shape matching the casting and known heat capacity, permanently connected to a tube coil (4), whose inlet (13) and outlet (14) nozzles extend outside the casting mould (1), the inlet nozzle (13) being connected by a flexible hose (5) with a proper cross-section to a compressed air supply module (6), provided with a supply collector (7) connected to a pneumatic network, a proportional air flow regulator (8), and an injector (9), which is connected to a proportional water flow regulator (10), connected to the water mains, while the outlet nozzle (14) is provided with a cooling medium temperature sensor (11), and the proportional air flow regulator (8), the proportional water flow regulator (10), and the cooling medium temperature sensor (11) are connected to an automatic solidification process control console (12).
- A method for controlling the solidification process in large-sized castings, characterised in that inside the casting mould there are mounted active cooling segments, made of at least two steel plates, with a shape matching the casting and known heat capacity, permanently connected to a tube coil, whose inlet and outlet nozzles extend outside the mould, wherein compressed air is introduced into the tube coils after filling the casting mould with hot metal, upon which its temperature is controlled in a continuous manner, and after reaching an air temperature of 105°C, water is introduced into the system and mixed with compressed air, generating water mist, which constitutes a cooling medium; further in the process, the pressure and flow of the coolant as well as the degree of saturation of air with water are controlled and adjusted, thus changing the intensity of heat extraction from the steel plates, upon which, when the temperature of the cooling medium drops below 105°C, the inflow of water is closed, and the cooling process ends when the temperature of the coolant drops below 80°C.
- The method according to claim 2, characterised in that the casting solidification process is controlled by means of a control console provided with an algorithm.
- The method according to claim 2 or 3, characterised in that the air flow rate has a value ranging from 300 to 1000 l/min.
- The method according to claim 2 or 3 or 4, characterised in that the degree of saturation of the cooling mixture with water mist is no higher than 5% in a volume ratio.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PL441973A PL441973A1 (en) | 2022-08-08 | 2022-08-08 | Control system for the solidification process in large-size castings and method of controlling the solidification process in large-size castings |
Publications (1)
Publication Number | Publication Date |
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EP4316689A1 true EP4316689A1 (en) | 2024-02-07 |
Family
ID=85800706
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP22205687.1A Pending EP4316689A1 (en) | 2022-08-08 | 2022-11-06 | Control system for the solidification process in large-size castings and process control of solidification in large-size castings |
Country Status (2)
Country | Link |
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EP (1) | EP4316689A1 (en) |
PL (1) | PL441973A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20130087995A (en) * | 2012-11-27 | 2013-08-07 | 유기철 | Temperature control system of multi channel mold for reduction cooling cycle time |
KR102181439B1 (en) * | 2019-11-21 | 2020-11-23 | 한국생산기술연구원 | Mold cooling control device |
KR20220071798A (en) * | 2020-11-24 | 2022-05-31 | (주) 진양기계 | Cooling system for low pressure casting apparatus |
-
2022
- 2022-08-08 PL PL441973A patent/PL441973A1/en unknown
- 2022-11-06 EP EP22205687.1A patent/EP4316689A1/en active Pending
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR20130087995A (en) * | 2012-11-27 | 2013-08-07 | 유기철 | Temperature control system of multi channel mold for reduction cooling cycle time |
KR102181439B1 (en) * | 2019-11-21 | 2020-11-23 | 한국생산기술연구원 | Mold cooling control device |
KR20220071798A (en) * | 2020-11-24 | 2022-05-31 | (주) 진양기계 | Cooling system for low pressure casting apparatus |
Also Published As
Publication number | Publication date |
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PL441973A1 (en) | 2023-07-10 |
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