DUAL SAND RECLAIMER

Abstract: A dual sand reclaimer comprising a drum 1 formed of an inner 10 and outer cylinder 9, substantially along its length, the drum being formed into three segments S₁, S₂, S₃, an entrance segment S₁ wherein the castings E are initially de­ posited for removal of its green mold sand, the inner cylinder 10 thereat being perforated to provide for separation of the sand from its castings, a middle segment S₂ wherein the cast­ ings and internally arranged mold sand are subjected to ab­ rasive members A that remove any core sand, and a third or discharge segment S₃ from which the castings exit, and having an inner cylinder 10 thereat perforated to provide for the passage of the core sand and abrasive members therethrough, with the sand being screened for removal thereat, while the abrasive members are returned by vanes 14 arranged intermediate the inner 10 and outer cylinders 9 of the middle segment S₂ of the drum 1 for a return to the leading end of the segment for reusage.

Description: This invention relates to a mold sand reclaimer as defined in the preamble of claim 1, and to a process for effecting mold sand reclaiming and its removal from cast iron parts as defined in the preamble of claim 11. Such a mold sand reclaimer and such a process are known from FR-A-2 296 484. The segments of the inner cylinder of the drum of the known reclaimer are identical in construction throughout the axial length of the drum. When the drum is rotated the sand encrusted castings deposited in the inner cylinder are tumbled and urgent to move longitudinally of the inner cylinder while the loosened mold sand falls therethrough, and is likewise moved longitudinally of the outer cylinder to a location for collection. Although the known reclaimer can be structurally arranged to provide for collection for the treated castings and the loosened mold sand separately either both at the same and or opposite ends of the reclaimer's cylinders the known reclaimer does not allow distinct types of sand such as clay mold sand and core sand to be removed from the castings separately and collected separately for reusage. Moreover, the known reclaimer permits the mold sand to be removed from the casting only by tumbling the castings. If the castings have internal cavities it is difficult to remove the mold sand from such cavities. The mere tumbling of the castings is not sufficient to remove the mold sand from internal cavities which the castings may have. An object of the invention is to provide a mold sand reclaimer of the kind defined in the preamble of claim 1, which mold sand reclaimer permits the complete removal of casting sand that yet clings upon the cast parts, whether such sand be adhered superficially to the cast part, or arranged within its internal apertures, in order that the different types of mold sand can be removed, and reasonably segregated as to the type of sand employed, for ready in preparation for reusage. Another object is to provide an improved process for eeffecting mold sand reclaiming and its removal from cast iron pats of the kind defined in the preamble of claim 11. The above stated objections are achieved by the features of the characterizing portion of claim 1 and claim 11 respectively. Another object of this invention is to provide for the removal of distinct types of sand from cast iron castings so as to not only prepare the castings for further working, but to have the distinct types of sand reasonably reclaimed for reusage. Another object of this invention is to provide a rotary shake-out dual sand reclaiming unit wherein the clay mold sand and the core sand can be reasonably separately reclaimed for further usage by the foundry. Another object of this invention is to provide a sand reclaiming device that is built significantly sturdy in its structure, so that it can handle heavy cast parts even in the category of engine blocks, and the like. Still another object of this invention is to provide a sand reclaiming unit where certain segments incorporate the standard and prior art type of abrasive members that have a tendency to scrub clean the castings passing therethrough, but likewise to enter into the interior of any cast part and to remove the mold sand even therefrom. Still another object of this invention is to provide means for removing all of the mold sand from a cast part, whether said mold sand be surface adhered or internally confined, all within a single and integrated dual functioning reclaimer apparatus. Still another object of this invention is to provide a sand shake out and reclaimer unit that is automatic of operation, and eliminates the need for any human participation during its normal and routine functioning. This invention contemplates the formation of a rotary shake out device designed, as previously explained, to furnish a separation of that residue sand from its just previously cast part. For example, in the molding of cast iron parts, as is readily and has long been know, mold sand is utilized for providing a particular shaped mold into which the molten cast iron is poured for providing a component as needed for a variety of applications within most segments of industry. In the formation of such a mold, and also which is well known, particular types and grades of sand are employed in the formation of the molds themselves. For example, for the general overall outline and shape of the external aspects of any part to be casts, generally a type of clay mold or green sand is employed, and which is prepared by the craftsman, or perhaps even mechanically performed this date, in furnishing the overall external configuration for the part to be molded. On the other hand, where internal chambers, cylinders, or the like, are required, within the intended cast part, a special type of sand is utilized, generally combined with particular chemicals to provide for its adhesion or adherence together, so that when the mold is formed, these internal chambers will be reasonably formed during the casting process, and that a fracture or failure of the molded internal components does not fail, which would lead towards the casting of an imperfect part, requiring rejection. On the other hand, the sand as utilized for formation of these internal features of a part to be cast is of a more expensive quality, usually, as previously explained, requiring chemical additives for assuring that the sand functions properly, and does not fail during the casting process. As a result, it is highly desirable to obtain a reclamation of this particular type of mold sand, for retreatment and reusage, and it is the style of apparatus as invented herein which is intended to provide for the salvage of such a mold sand for reapplication. On the other hand, it cannot be gainsaid that the standard clay or green sand likewise is desired for reclamation, and therefore, the structure of this current shake-out unit is intended to provide reasonably discrete or separate dual removal of the various mold sands from any casting passing through the apparatus, and for their separate collection in preparation for reusage. The structure of this current invention includes a drum means, supported by a base member, with the base member incorporating the required bearings for providing a reduced frictional rotation of the drum upon the same, while further embodying the drive means, such as a motor, or the like, for affording that moderate rotation for the drum during its functioning. The drum means of the apparatus includes a pair of cylinders, an outer cylinder having an inner and concentric cylinder arranged therein, with a vane means generally of the helical style being provided partially at select locations within the space intermediate these two cylinders, to provide for transfer of either the sand or other members during the apparatus functioning. The inner cylinder is constructed of a series of segments, the first segment comprising an entrance segment into which the castings are initially introduced into the apparatus, so that that surface clay mold or green sand normally adhering thereto, and which forms the basic exterior aspects of the mold, as previously explained, can be readily removed through tumbling of the cast parts therein. The inner cylinder incorporates means for effecting a gradual longitudinal shifting of the castings, down the length of the drum, and this can be provided through the application of rifling, or the like, upon the interior surface of the entrance segment. In addition, the entrance segment incorporates a series of perforations within or through its inner cylinder, so that while the green sand is removed, it readily falls through these openings and into that spacing where the helical vanes move said sand in a specified direction for disposal and collection for reusage. The apparatus is further formed integrally, with a middle segment, generally comprising its inner cylinder having a series of riflings or other means for moving the castings further longitudinally thereof. In addition, this particular segment of the apparatus further incorporates a volume of abrasive members, not too unlike tumbling balls, but in this particular instance, comprising what is generally identified in the trade as ductile star members or burnishing members, which have a tendency to abrasively rub against the cast component, and enter into its internal cavities, as formed, for removing what is identified as the core or cling sand that previously had been used within the mold for forming the inner structural aspects that give rise to the apertures or internal chambers formed desirably of the cast component during its formation. The ductile stars or abrasive media are available from a variety of sources. For example, as can be seen from the patent drawings accompanying this disclosure, engine blocks are the items that had been molded from cast iron, and while it is relatively easy to remove the surface or green sand from the castings, as they move through the initial or first segment of the apparatus, attempting to clean and eliminate the core sand from within the internal interstices formed of the casting, such as where the piston cylinders are formed, or the cam shaft may be located at the downward portion of any block, has been rather difficult in the past, usually requiring manual services. But, through the combination of the rotary apparatus of this invention, including an ample quantity of star abrasive media therein, the core sand is readily cleaned and easily removed from the cast parts, and becomes intermingled with the abrasive members as they likewise move with the cast parts longitudinally along the apparatus during its functioning. A third or exit segment of the apparatus is formed having a perforated inner cylinder, as can be seen, through which the abrasive members and the combined core sand falls, while the castings are moved by means of rifling, or the like, therefrom, and discharged or removed from the back end of the operating apparatus. The structured device includes means for initiating a return of the abrasive members and perhaps its combined core sand back towards the front of the apparatus, while separation of these two compenents readily occurs through the arrangement of a series of perforation provided through the outer cylinder, through which the core sand is allowed to be discharged, while the abrasive members being too large to pass through the outer cylinder apertures enter into the vaned spacing provided intermediate the inner and outer cylinders formed of the middle segment, and are returned to a housing provided between the first and middle segments, for transfer back into the middle segment, onto the surface of its inner cylinder, for reusage in aiding in the removal of the core sand from further deposited castings. Brief Description of the Drawings In referring to the drawings, Figure 1 provides an sometric view of the dual sand reclaimer of this invention; Figure 2 provides a view similar to Figure 1, with the drum being partially removed for disclosing its internal structure; Figure 3 provides a side view of Figure 1; Figure 4 is an entrance end or left side view of the invention as shown in Figure 1; and, Figure 5 is a discharge end or right end view of the invention as shown in Figure 1. Description of the Preferred Embodiment In referring to Figure 1, the dual sand reclaimer of this invention is disclosed. It comprises the drum means 1 mounted upon its base means 2 and disposed for rotation thereupon, through the riding of its integral tracks or races 3 upon bearings, generally provided as at 4, upon said base means. As can be seen further in Figure 3, a drive means, such as a motor 5 and which may function in cooperation with a speed reducer, as at 6, provides for a turn of the rotary drum through an intergearing with the circumferential gear 7 of the drum means. See also Figure 2. A cover, such as at 8, may provide enclosure for the gear means 7. It is to be noted that the base means 2 is fabricated from a series of bracing, struts, and pads, in order to afford full stability for the support of this sand reclaimer during its operations, and to minimize any vibrations, or the like, during its usage. As can be seen in Figure 2, the drum means 1 is fabricated of a pair of cylindrical members, such as an outer cylinder 9 and an inner cylinder 10. Generally, there are a series of helical vanes 14 provided intermediate the spacing 11 formed between these two cylinders, and these vanes are designed for providing for conveyance of any casting sand deposited therein during operations of this apparatus. As previously summarized, this sand reclaiming unit is useful and higly effective during rotation of the drum means for removing the mold sand from the castings following their manufacture. For example, as can be seen in Figure 2, engine motor castings F are being cleaned within the apparatus. Within this initial segment S₁ of the unit, the surface mold sand or green sand is generally removed from the exterior of the castings through tumbling, and such green sand is generally shown in separation as at G. As this occurs, the castings move gradually longitudinally down the length of the apparatus, through the movement caused by the arrangement of rifling or the like, as at 12, formed upon the surface of the inner cylinder. And the inner cylinder incorporates a series of openings, or perforations, as at 13, and as can be generally seen, in order to allow the reclaimed sand to fall therethrough, into the spacing 11 and therein be urged by operations of these helical vanes 14 in a direction for eventual discharge. In this particular instance, as can be seen, the vanes 14 are angled so as to provide for a shifting of the sand contained within the spacing 11 rearwardly, towards the entrance of the reclaimer, as the drum means 1 rotates in this instance in a counterclockwise direction. Thus, the sand will fall from the entrance end edge 15 of the unit, and therein be collected for reusage, as previously summarized. On the other hand, it is just as likely that the surface of the outer cylinder 9 could be provided with a series of openings, or perforations, or even a screened portion (all of which is not shown), in order to allow for the reclaimed sand to fall at any particular location along its length and be collected for reusage. It can also be seen that the perforated inner cylinder 10 may be formed of a series of segmented sections, and which are held together in a manner as previously explained and shown in FR-A-2 296 484 (≙ US-A-3 998 262). In addition, a retaining means or ring section 16 is provided at the entrance end of the drum 1, within the inner cylinder 10, and therein provides a means for retention of the inner cylinder 10, or its segmented sections, together, to form a unified inner cylinder surface for operating to separate the green sand from its castings, as previously explained. The retainer ring 16 may incorporate a series of outwardly extending projections 17, and which afford openings, as at 18, therebetween, so as to provide a space through which the green sand may eventually be discharged from the apparatus, after its urging to proximate this end of the drum through the functioning of the helical vanes 14. The inner cylinder 10 includes a middle segment, as at S₂, and within this particular segment the inner cylinder is formed as an annular surface, as at 19, which may likewise be formed of a series of segmented sections, secured together in the manner as previously explained in US-A-3 998 262. In addition, the segments of the inner cylinder at this location, or within this middle segment, includes a series of rifling, as at 20, to insure the continuing movement of the castings, such as the motor blocks E, therealong, during the rotation of the drum means 1. And, as can also be seen in Figure 2, the segments of the inner cylinder may be formed integrally, having the rifling 20 formed upon each segment and integrally extending outwardly therefrom may be the helical vanes 14, as previously explained. Within this middle segment S₂ of the reclaimer, there is also deposited an ample quantity of abrasive members, as can be seen at A, and these abrasive members are of the type as previously explained which are available in the art for functioning as means for deburring or cleaning other components. In any event, and also as explained, during the functioning of this middle segment S₂ of the reclaimer, these abrasive members A have a tendency to etch their way into the interior of the shifting castings E, and provide a clean out of that core sand normally arranged interiorly thereof and which was required to provide for the interior shaped configuration for the casting during its initial molding. In any event, these abrasive members have a tendency to scrub the interior of the casting, while likewise remove any residual surface green sand that may yet be contained or adhered to the external surface of the casting passing through this apparatus. As the combination castings E, the abrasive members A, and any loosened preferably core sand reach the end, approximately at 21, the combination enters into the third segment S₃ of the unit. At this particular location, the inner cylinder of the apparatus is formed as a perforated member, as at 22, providing a series of openings which are obviously too small to allow any casting to pass therethrough, but which allows for the combined abrasive members A and any loosened mold sand to pass through the perforated cylinder, and into the spacing 23 arranged intermediate the inner and outer cylinders. At this juncture, the disposition of an inclined or truncated shaped member 24, in the nature of a plate, is provided therein, and inclines in a direction towards the intermediate section S₂, and thereby allows for the back flow of the combined abrasive members and sand towards the spacing arranged intermediate the inner cylinder 10, and the outer cylinder 9, at this location. When this occurs, the sand falls through the grading or screening member 25 formed of a series of perforations provided through the outer cylinder 9, but that the openings provided thereat are too small to allow for the passage of the abrasive members A therethrough. Thus, the abrasive members are picked up by the helical vanes 14, and forced towards the entrance end, or the left end, of the unit as shown in Figure 2. Thus, the abrasive members are urged the entire length of the intermediate section S₂, or until such time as they enter into a formed housing 26 provided between the entrance and intermediate segments S₁ and S₂ of the reclaimer. This housing is formed as an annulus, as can be seen, having an opening provided therein, with entrance apertures 27 providing for the admission of the abrasive members A into the housing 26, and their eventual falling through the series of apertures 28 provided through the top surface of the housing 26, as can be seen. Thus, at this location, the abrasive members A are deposited once again into the front or leading end of the middle segment S₂, where they again combined with any castings deposited within the apparatus and which are moving through the reclaimer during its operation. As previously explained, the inclined plate or truncated member 24 within the third section S₃ of the apparatus is designed to provide for an urging of the combined sand and abrasive members A back towards the middle segment S₂. On the other hand, it is just as likely that the inclined plate 24, in addition to the adjacent surface of the outer cylinder 9, within the formed section S₃, could be perforated, and allow the core sand to fall therethrough, and be collected at that location, rather than slightly forwardly thereof, as shown through the perforated section 25 formed at the discharge end of the middle section S₂, as disclosed. In any event, and regardless of where the perforations 25 may be located, whether they be at the position as shown at the end of the middle section S₂, are entirely or partially through the outer cylinder 9 within the third section S₃, it is desired that this core sand be collected, for ready cleaning, retreatment, and for reusage for forming those internal mold segments for any future casting to be formed. It might be commented that during the operations of this particular invention the drum means will normally be rotated at a velocity of approximately a fraction or to a plurality of revolutions per minute, but that this rotation for the combined cylinders can be varied, depending upon the type of castings being cleaned, and the size and weight of these cast members. Obviously, when motor blocks as at E are being cleaned, the revolutions of the drum means will be slowed considerably. In the construction of a prototype of this development, to give an example of the type of dimensions that may be used in one embodiment, as for example that which may be designed for removing mold sand from motor blocks, the unit may be approximately 7.32 m (24 feet) in length, the outer cylinder may have an outside diameter of approximately 1.22 m (48 inches), while the inner cylinder has a diameter of approximately 0.99 m (39 inches). The various perforations provided within or through the drum means should be of sufficient dimensions so as to allow for the passage of the identified materials therethrough. For example, the perforations provided within the inner cylinder 10 of the segment S₁, in addition to the perforations 25, of the outer cylinder 9, should be of sufficient size so as to allow passage of the molding sand therethrough. Furthermore, the perforations 22 formed through the inner cylinder of the discharge segment S₃ should be of sufficient dimension so as to allow the combined passage of the star media G in combination with the mold sand therethrough, and generally these dimensions will be in the order of approximately 2.54-7.62 cm (1-3 inches), or greater or smaller, generally depending upon the size of the media G used for scrubbing the inner arranged cavities of the castings E being cleaned. Obviously, these dimensions will vary depending upon the size of castings being treated. In any event, and regardless what speed or size of unit is used, this reclaimer device is highly effective for providing for the reasonably discrete separation of the differing sands, such as the green mold sand or the core sand from their castings, with each sand being substantially collected separately, and for ready repreparation for a usage again in the molding process.

Claims: A mold sand reclaimer for use for removal of the mold casting sand from a molded cast iron part, comprising a rotary drum (1), a base means (2) supporting the drum (1) for rotation, bearing means (4) provided upon the base means (2) and supporting the drum (1) during said rotation, drive means (5) provided with the base means (2) and furnishing the drum (1) with its slow speed of rotation, said rotary drum (1) comprised of a pair of cylinders (9, 10), one cylinder being an outer cylinder (9), the other cylinder being an inner and concentric cylinder (10) of the outer cylinder (9), there being a spacing (11) provided between the two said cylinders (9, 10), a series of helically arranged vanes (14) provided at least partially between the two arranged cylinders (9, 10) and within the formed spacing (11), said inner cylinder (10) having openings (13, 22) provided therethrough for passage of the removed sand (G) to the cylinders' (9, 10) intermediate spacing (11) and being formed of a series of segments (S₁, S₂, S₃) of which a first segment (S₁) is an entrance segment provided for the entrance of the castings (E) therein and effecting removal of the surface disposed mold sand (G) therefrom as during tumbling of the castings (E), said first segment (S₁) having means (12) provided therewith for moving the castings (E) longitudinally therealong, said first segment (S₁) having a series of said openings (13) provided therethrough for passage of the removed sand (G) to the cylinders' (9, 10) intermediate spacing (11), said vanes (14) thereat providing for movement of the sand for disposition, a second segment (S₂) of the inner cylinder (10) having means (20) provided therewith for moving the castings (E) longitudinally therealong, characterized in that said inner cylinder (10) is formed of three segments (S₁, S₂, S₃) of which the middle segment (S₂) being said second segment is provided for accommodating a supply of abrasive members (A) that aid in the removal of the mold sand from the inner areas of any casting (E) transversing therealong, the third segment (S₃) of the inner cylinder (10) having a series of said openings (22) therethrough and providing for the separation of the loosened sand and the abrasive members (A) from the casting (E) and with the sand and members (A) passing into the spacing (23) between the two said cylinders (9, 10) while said castings (E) are discharged from the drum (1), means (24) provided between the cylinders (9, 10) within the third segment (S₃) for moving the members (A) towards the vaned spacing (11) between the cylinders (9, 10) within the middle segment (S₂) for a return to the middle segment (S₂) of the inner cylinder (10) while effecting a disposition of the middle segment loosened sand from the drum (G). A reclaimer according to claim 1 wherein said middle segment (S₂) of the inner cylinder (10) has a leading end and a discharging end, said vanes (14) between the middle segment (S₂) of the inner cylinder (10) and the outer cylinder (9) moving said abrasive members (A) to approximately the leading end of the middle segment (S₂) and for discharge back into the middle segment (S₂) for reusage. A reclaimer according to claim 1 or 2 and including a retaining means (16) holding said inner cylinder (10) at the entrance segment (S₁) within the outer cylinder (9), and said retaining means (16) having openings (18) provided therethrough for disposition of the entrance segment removed sand thereat. A reclaimer according to claim 3 wherein said retaining means comprises a ring means (16), said ring means (16) including a series of outward projections (17) arranged in proximity with the outer cylinder (9) and providing openings (18) between the said projections (17) for disposition of the sand being removed. A reclaimer according to anyone of the preceding claims wherein said first segment (S₁) of said inner cylinder (10) is sectionalized. A reclaimer according to anyone of claims 2 to 5 and including a housing (26) arranged intermediate the first and middle segments (S₁, S₂) of the inner cylinder (10) and proximate the leading end of the latter, said housing (26) having openings (27) communicating with the space between the middle segment (S₂) of the inner cylinder (10) and the outer cylinder (9) and disposed for receiving therein the abrasive members (A) being returned by the vanes (14), and said housing (26) having further openings (28) for discharging the members (A) into the middle segment (S₂) of the inner cylinder (10) for reusage. A reclaimer according to anyone of the preceding claims wherein means (9, 24, 25) are provided for effecting a disposition of the middle segment loosened sand from the drum (1) said means comprising the outer cylinder (9) having a series of openings (25) therethrough for discharge of the sand while retaining the abrasive members (A). A reclaimer according to anyone of the preceding claims wherein the means (24) provided between the cylinders (9, 10) within the third segment (S₃) for moving the abrasive members (A) comprises an inclined member (24) sloped to direct the members (A) towards the said vaned spacing (11) between the middle segment (S₂) of the inner cylinder (10) and the outer cylinder (9). A reclaimer according to claim 8 wherein said inclined member (24) also has a series of openings therethrough for passage of the mold sand while retaining the abrasive members (A) thereon for movement towards the vaned spacing (11) between the middle segment (S₂) of the inner cylinder (10) and the outer cylinder (9). A reclaimer according to anyone of the preceding claims wherein said means (12, 20) provided upon the entrance and middle segments (S₁, S₂) of the inner cylinder (10) for moving the castings (E) longitudinally thereof comprises rifling (12, 20). A process for effecting mold sand reclaiming and its removal from cast iron parts, comprising the steps of providing a drum means (1) formed of an inner (10) and outer (9) cylinder with a degree of rotation, introducing castings (E) to be cleaned into an entrance segment (S₁) of the inner cylinder (10) of the drum means (1) wherein the castings (E) are moved longitudinally along the rotating drum means (1), while its loosened surface mold sand (G) is freed therefrom and passes through perforations (13) formed within the entrance segment (S₁) of the inner cylinder (10) of the rotating drum means (1), passing said castings (E) further along said rotating drum means (1) and into a middle segment (S₂) of the inner cylinder (10), tumbling said castings (E) therein while moving them longitudinally along said middle segment (S₂) to a discharging segment (S₃) of the inner cylinder (10) of the drum means (1), and discharging the castings (E) from the discharging segment (S₃), characterized by exposing the castings (E) in the middle segment (S₂) to a core sand loosening abrasive media (A) for removing the core sand from within the internal cavities formed within the moving castings (E), further passing said combined castings (E), loosened core sand, and abrasive media (A) towards and into said discharge segment (S₃), discharging the castings (E), while screening for a separation of the abrasive media (A) from the loosened core sand, discharging for collection the loosened core sand while passing the abrasive media (A) intermediate the middle segment (S₂) and the outer cylinder (9) for transfer back to the leading end of the said middle segment (S₂) and for their deposition therein for further cleaning of additional castings (E).

Inventors: DIDION, CHARLES J.
Applicants: DIDION MANUFACTURING COMPANY
Application year: 1986
Main classification: B22D31
IPC codes: B22D31, B22C5