Molten metal pouring device

An improved apparatus for pouring molten metal into a mold or other cavity. The apparatus includes a tiltable pouring ladle having a pouring spout disposed coaxially with the axis of rotation or tilt of the ladle to permit pouring of metal in a direction coincident with such axis of rotation. The apparatus is further provided with a positionable pouring trough for directing molten metal from the pouring spout to a pouring cup located at any position on the mold surface. With this apparatus, a fixed relationship between the pouring spout, the pouring trough, and the mold surface at any phase of the pouring process may be maintained such that the trajectory of molten metal being poured through air is minimized. The ladle is shaped such that molten metal may be poured at a rate proportional to the tilting rate of the ladle. The ladle also includes apparatus for preventing impurities such as slag or dross inclusions introduced into the ladle with the molten metal from being poured into the casting. The entire apparatus is contained within a frame permitting it to be readily attached to a coventional crane or monorail system as an easily effected substitute for a conventional manual pouring device.

BACKGROUND OF THE INVENTION 
This invention relates to apparatus for manually pouring molten metal into 
a mold during a metal casting process and, in particular, to an improved 
tiltable ladle which permits pouring of molten metal under operator 
control whereby metal spillage, heat loss from the molten metal during 
transfer to the mold and required operator concentration may be minimized. 
In the manual metal casting industry, castings are poured from manually 
controlled pouring ladles which have been filled with molten metal at a 
molten metal source and transported by crane or by a monorail system to 
the molding area where the metal is poured from the ladles into the 
individual molds. These conventional pouring ladles are cylindrical in 
shape about either a vertical or horizontal axis, but in some instances 
are segmental in shape about a horizontal axis, and are fitted with a 
pouring lip or spout. In normal foundry practice today, these ladles are 
rotated about a horizontal axis to permit metal to overflow the pouring 
lip and spill from the ladle in a direction perpendicular to the axis of 
rotation or tilt of the ladle and directly into a pouring cup on the mold 
surface. Furthermore, although not in general practice today, it is known 
that molten metal also may be poured into runner boxes for directing the 
molten metal to a pouring cup on the mold surface instead of pouring 
directly into the pouring cup. Such previously known pouring ladles are 
shown, for example, in U.S. Pat. No. 284,005 to Hainsworth; U.S. Pat. No. 
4,025,060 to Fujie; and U.S. Pat. No. 4,112,998 to Sato. 
The requirements for pouring a satisfactory mold can be quite rigid, 
depending upon the design of the casting to be poured. In general, these 
requirements are as follows: 
1. The metal must have sufficient temperature to flow properly within the 
mold cavity. 
2. Metal flow must be commenced and maintained at a sufficiently rapid rate 
of flow to maintain a level of metal within the pouring cup throughout the 
pour, preventing inpurities floating on the metal surface being carried 
into the mold cavity. 
3. Metal flow must be maintained continuously throughout the pour. 
4. Metal pressure within the mold must be held to a level that will prevent 
damage to the mold interior. 
In addition to the above, the economics of production require that pouring 
be terminated before metal has overfilled the pouring cup and run out over 
the mold surface and solidified. 
With a conventional pouring device, where pouring is directed perpendicular 
to the axis of rotation of the ladle such as shown in U.S. Pat. No. 
4,112,998 to Sato, the physical configurations of the mold and the pouring 
device usually prevent the pouring lip of the device from being brought 
into close proximity with the pouring cup. Thus, the molten metal 
trajectory to the pouring cup must be directed accurately to fulfill the 
requirements of a satisfactory pour. If the pouring cup position changes 
from mold to mold, the molten metal trajectory must be changed requiring 
high operator skill and concentration to avoid excessive spilling and 
damage to the casting. Furthermore, with front lip pouring ladles, 
substantial heat loss of the molten metal occurs when the molten metal 
stream passes through the air in a trajectory between the pouring ladle 
and the pouring cup. This heat loss increases with the length of this 
trajectory. 
It should therefore be apparent that proper pouring from front lip pouring 
ladles directly into a pouring cup or into a transfer trough requires a 
high degree of operator coordination and extreme concentration. When it is 
also considered that the operator is working in a very hot and dirty 
environment and that any slight miscalculation of metal trajectory or flow 
will result in the probable splashing and loss of molten metal or the 
destruction of a casting, it is obvious that a great need exists for a 
device to optimize operator performance and minimize required operator 
skills. 
There are other conventional pouring devices generally used in a continuous 
iron pouring line which have ladles which pour in direction coincident 
with the axis of rotation of the ladle during pouring. Such ladles are 
shown in U.S. Pat. Nos. 3,940,021; 3,997,461 and 4,044,927. In all of 
these devices, the ladles are provided with nozzles to pour directly into 
the pouring cup in a mold. The iron pouring lines are automatic and the 
molten metal is always poured to the same location. This apparatus cannot 
be used when the pour cup changes from mold to mold such as in a manual or 
custom foundry. 
SUMMARY OF THE INVENTION 
The present invention overcomes the disadvantages of prior manual pouring 
devices by providing a versatile pouring ladle for pouring molten metal 
from the ladle to any point on a mold surface. 
A manually operated ladle is provided having a pouring spout coincident 
with the axis of rotation of the ladle to permit pouring along the axis of 
rotation. The ladle is elongate and has a generally "U" shaped cross 
section perpendicular to the longitudinal axis. With this configuration, 
the ladle can carry more molten metal than a conventional sector shaped 
ladle of the same height, width and length. 
The molten metal is poured through the spout into a trough which directs 
the molten metal to any desired location on the mold surface. 
The ladle further includes a baffle between a metal receiving compartment 
and a metal pouring compartment which has a metal transfer slot located 
such that during most of the pouring range of the ladle, the metal 
transfer slot lies below the molten metal surface. This baffle acts to 
confine most of the slag and dross inclusions within the receiving 
compartment during pouring. Refractory design of the interior of the ladle 
provides a constant metal surface area within the ladle bowl at all ladle 
tilt angles within the pouring range of the ladle to provide a constant 
pouring rate as the ladle is tilted at a constant rate. 
With the present invention, the manual pouring is accomplished with less 
operator concentration than with prior manual pouring devices. 
Furthermore, heat losses caused by the molten metal traveling through air 
are minimized by minimizing the distance between the pouring spout and the 
trough as well as the distance between the trough discharge end and the 
pouring cup on the mold. 
Furthermore, the ability to maintain a fixed trough location relative to 
the pouring cup, coupled with control of the rate of metal flow permits 
the maintenance of nearly constant metalstatic pressure within the mold 
during the casting process.

DESCRIPTION OF A PREFERRED EMBODIMENT 
A molten metal pouring apparatus 10 according to the present invention is 
shown in FIGS. 1, 2 and 3. The apparatus includes a ladle 30 which may be 
tilted about a longitudinal axis of rotation 32 to pour molten metal 
contained within the ladle. The ladle 30 is generally elongate along the 
axis of rotation and has a generally "U" shaped cross section 
perpendicular to the axis of rotation. This apparatus includes a frame for 
supporting the ladle 30 comprising a top bail member 12, joining two side 
support members 14 and 16 and also a lower stabilizing bar 18 joining the 
two side support members 14 and 16. The bail member 12 has a bar handle 20 
which is held by a conventional hook 22, chain 24 and hoist 26 riding on 
an overhead track 28. 
The ladle 30 is provided with a tubular pouring spout 34 which is disposed 
on an end wall 36 of ladle 30 with the longitudinal axis of pouring spout 
34 coincident with the longitudinal axis of rotation 32. Ship channel 
members 38 are mounted on each end wall of ladle 30 with the closed end of 
the channels affixed to the end walls of ladle 30 as by welding. All ship 
channel members 38 are bent in a curvilinear shape and are affixed to end 
walls of ladle 30 radially spaced from and concentric to the pouring spout 
34. Cable guide members 40 are affixed to an outer leg of the curved ship 
channel members 38 for carrying lifting cables 42. In a preferred 
embodiment, there are two lifting cables 42 on each end of the ladle 30. 
One terminal end of each of the lifting cables 42 is affixed in a 
conventional manner to corresponding anchor portions 44 which form a 
portion of the cable guide members 40. 
The other terminal ends of lifting cables 42 are received by and affixed to 
connectors 46, as shown in FIGS. 1 and 4, which have threaded upper 
portions 48. The threaded portions 48 are received through bores 50 in 
lifting members 52 and nuts 54 are then threaded on the threaded portions 
48 extending through bores 50 whereby lifting cables 42 are held and 
retained by lifting members 52. FIG. 4 is a detailed view showing the 
connection of one pair of lifting cables 42 to a lifting member 52. The 
other pairs of lifting cables 42 at the other end of ladle 30 are 
connected similarly to another lifting member 52. Each lifting member 52 
has interior threads 56 for engaging threads 58 of a machine screw support 
rod 60. The lower end of machine screw support rod 60 is supported by a 
conventional machine screw bearing 62 affixed to a supporting member 64. 
The supporting member 64 is bolted at one end to a projecting member 66 
which is affixed as by welding to the respective side support members 14 
and 16 as shown in FIGS. 2 and 4. A telescoping cover 68 surrounds the 
threads 58 of machine screw support rod 60 between the lifting member 52 
and the bearing 62 as shown in FIG. 4 to protect the threads during use of 
the metal pouring apparatus. 
The upper end of each of the machine screw support rods 60 engages 
conventional intermediate gearing assemblies 70 as shown in FIG. 1, which 
in turn engages conventional drive gearing assemblies 72 mounted at one 
end of drive shaft 74. The drive shafts 74 are connected to a conventional 
reversible variable speed drive motor 76. Drive gearing assemblies 72, 
intermediate gearing assemblies 70 and machine screw support rods 60 are 
all conventional assemblies such as Jactuator manufactured by Duff-Norton 
Company. The housings of intermediate gearing assemblies 70 and drive 
motor 76 are mounted on bail plate 12 as shown in FIGS. 1 and 2. 
A lifting member cam follower 78 is mounted on each of the lifting members 
52. These cam followers 78 ride in lifting member cam guides 80 mounted on 
side support frames 14 and 16 as shown in FIGS. 1 and 2 to prevent 
rotation of the lifting members 52 when machine screw support rods 60 are 
rotated by drive motor 76 to move lifting members 52 upwardly or 
downwardly. 
An upper telescoping cover 82 is connected between the top of each lifting 
member 52 and bail plate 12 as shown in FIG. 4 to protect the upper 
threads of machine screw support rod 60 during operation. 
During tilting, ladle 30 is guided with respect to the structural framework 
provided by side frame supports 14 and 16, bail plate 12 and lower 
stabilizing bar 18 by cam followers 84 mounted on side frame supports 14 
and 16 as shown in FIG. 2. These cam followers 84 ride in the "U" shaped 
channel 86 provided by ship channel members 38 mounted on the ladle 30. 
To rotate the ladle 30 for pouring molten metal contained therein an 
operator actuates drive motor 76 whereby machine screw support rods 60 are 
rotated in lifting members 52. The drive motor 76 is actuated by an 
operator using conventional control apparatus (not shown). Depending on 
the direction of rotation of machine screw support rods 60, the lifting 
members 52 move upwardly or downwardly. If lifting members 52 are moved 
upwardly, they draw lifting cables 42 with them thereby rotating the ladle 
30 about the axis of rotation 32 of the ladle which extends through the 
spout 34. The ladle 30 is guided during the rotation by cam followers 84 
riding in the "U" shaped channel 86. 
In a preferred embodiment, ladle 30 has a steel outer wall 88 and a 
refractory lining 90 as shown in FIG. 5 to contain the molten metal. The 
interior of ladle 30 is divided by a refractory baffle wall 92 between a 
metal receiving chamber 94 and metal pouring chamber 96. Molten metal can 
flow between the chamber through a metal transfer slot 98. Metal transfer 
slot 98 is positioned near the bottom and front wall of ladle 30 so that 
it will remain beneath the molten metal surface during all but the final 
stages of emptying ladle 30 thereby preventing impurities which normally 
float on the molten metal surface from entering the metal pouring chamber 
96 and ultimately the casting itself. 
In a preferred embodiment, the refractory liner 90 contains an offset, 
generally designated as 100, designed to maintain a constant metal surface 
area at all angles of tilt of ladle 30 throughout the pouring range. 
As the ladle 30 is rotated about the axis of rotation 32 by activation of 
drive motor 76, molten metal will be poured out spout 34 from the metal 
pouring chamber 96. Further, this molten metal is replenished by molten 
metal contained within the receiving chamber 94 through metal transfer 
slot 98. 
As seen in FIG. 2, a refractory lined metal cover 102 may be placed over 
the open upper portion of ladle 30. This cover 102 is held in place on 
ladle 30 by nut and bolt arrangement 104 cooperating with slots 106 in 
cover 102. With this arrangement cover 102 may be removed for refractory 
liner replacement or repair. An opening is left in metal cover 102 over 
the metal receiving chamber 94 through which the ladle 30 can be refilled 
after emptying. This opening is covered by a movable door 108 rotatably 
mounted to a rodlike movable cover handle 110. Each end of cover handle 
110 is rotatably mounted on pins 112 affixed to the cover 102 so that the 
movable door 108 may be swung away from the opening metal cover 102 when 
the ladle 30 is to be replenished with molten metal. 
Molten metal from ladle 30 is poured into a metal transfer trough 112 for 
delivery to any selected pouring cup 114 in a mold 116 as shown in FIGS. 1 
and 7. The metal transfer trough 112 is shown in FIG. 6 and includes a 
trough 118 slidably mounted on a trough support plate 120 which in turn is 
affixed as by welding to side support frame 14 as shown in FIG. 1. The 
trough support plate 120 includes a slot 122 through which extends a 
conventional trough clamp 124, for example, a Knu-Vise Model #CAV 1200 
obtained from Lapeer Mfg. Co. The trough 118 includes a projecting clamp 
mounting plate 127 affixed as by welding thereto. The trough clamp 124 
includes a bolting plate 126, which is bolted to mounting plate 127, and a 
guide member 128, mounted transversely to bolting plate 126, which rides 
in slot 122. The trough clamp 124 further includes a lower clamp member 
(not shown) which clears the lower surface of plate 120 during movement of 
the trough 118 on plate 120 and an over-center mechanism 129 actuated by 
handle 130. In one position of handle 130, trough clamp 124 clamps trough 
118 to support plate 120 by frictionally clamping lower clamp member (not 
shown) against plate 120. In the other position, the trough 118 is 
released and may be moved in the direction of slot 122. Trough handle 132 
is provided to facilitate the positioning of trough 118. 
The trough 118 is further provided with an upwardly extending side member 
119 and a parallel upwardly extending side member 121, as shown in FIG. 6. 
The height of side member 119 is less than the height of side member 121 
so that during pouring, when spout 34 rests near the top surface of side 
member 119 and pouring commenced, the side member 121 will reduce or 
prevent spillage of molten metal as the molten metal splashes against side 
wall 121. 
The slot 122 runs perpendicular to the axis of rotation 32 of ladle 30 as 
shown in FIG. 7; thus the discharge end of metal transfer trough 118 may 
be laterally positioned with respect to the axis of rotation of ladle 30 
to a selected pouring cup 114 on the mold 116. 
To align the end porition of metal transfer trough 118 with a particular 
pouring cup 114 on mold 116, the operator manually moves the entire metal 
pouring apparatus 10 with hoist 26 riding on overhead track 28 in the 
direction "A" as shown in FIG. 7 until the metal transfer trough 118 is 
longitudinally aligned with the pouring cup of interest, for example, 134 
as shown in FIG. 7. The operator then releases trough clamp 124 and 
adjusts the lateral position of the metal transfer trough 118 by handle 
132 in the direction "B" until the discharge end of metal transfer trough 
118 is properly aligned with pouring cup 134 on mold 116 at which time he 
then locks the metal transfer trough 118 in position with trough clamp 
124. By positioning apparatus 10 with respect to the mold 116 as shown in 
FIG. 7, it is possible to pour to any pouring cup on the mold surface 116. 
To pour molten metal into the pouring cup 134, the ladle 30 is tilted by an 
operator actuating drive motor 76 from a non-pour position shown in solid 
lines in FIG. 8 to the full tilt position shown in dotted lines in FIG. 8 
and molten metal is poured through spout 34 as shown in FIG. 8 into trough 
118 and thence to pouring cup 134. All this being done at a rate 
determined by and under control of the operator. 
Thus, with this apparatus, the operator has improved control for directing 
molten metal to a selected pouring cup thereby minimizing metal spillage 
and required operator concentration. Furthermore, the operator has optimum 
control over the pouring rate, and with the position of the pouring spout 
34 and metal transfer trough 118 securely maintained during pouring, the 
operator can maintain nearly constant ferrostatic pressure within the mold 
through the entire pouring operation. In addition, since the pouring spout 
34 is closely adjacent to the metal transfer trough 118, and the discharge 
end of the metal transfer trough 118 is closely adjacent to the pouring 
cup on the mold, the molten metal trajectory through air is minimized, 
thereby minimizing heat loss from the molten metal during delivery to the 
mold. 
While the fundamental novel features have been shown and described, and 
while the basic invention is intended for application as a manual pouring 
device, it should be understood that various substitutions, modifications 
and variations may be made by those skilled in the art without departing 
from the spirit or scope of the invention. Accordingly, all such 
modifications and variations are included in the scope of the invention as 
defined by the following claims: