CONTINUOUS CASTING MACHINE OF ENDLESS TRACK TYPE

Abstract: The casting machine comprises a plurality of mould blocks (1) connected to form two endless tracks (2) situated one above the other and having respective runs which cooperate to define a mould cavity (3) and which, in use, are moved in the same direction. Each endless track (2) passes around gears (12,13) at the upstream and downstream ends of the mould cavity (3). An endless chain (29) passes around sprockets mounted coaxially on the shafts of the gears (12,13) of each mould assembly (2) and drivingly couples them. Tensioner means (32) are arranged to produce a tensile force in the endless chain (29) and thus to urge the mould blocks (1) in the associated said run towards one another. Each endless track has a horizontal cooling run (10) and the mould blocks in this run may also be urged together by a similar endless chain (35) and tensioner means (38) acting on sprockets (33,34) mounted on the shafts of gears (11,12′) engaging the endless tracks at the upstream and downstream ends of the cooling zone (10).

Description: The present invention relates to continuous casting machines and is concerned with such machines, according to the preamble of claim 1, which are of endless track type and comprise a plurality of mould blocks connected to form two endless tracks having respective runs which cooperate to define a mould cavity and which, in use, are moved in the same direction, each endless track passing around guide means, e.g. gears, at the upstream and downstream ends of the mould cavity (JP-A- 60 24 0356). Figure 1 is a diagrammatic side elevation of a known casting machine of this type. The machine comprises a plurality of mould blocks 1 interconnected to form two endless tracks constituting mould assemblies 2. The two mould assemblies 2 are disposed in vertically opposed relationship with respective opposed horizontal runs which define a mould cavity 3. A tundish nozzle 5 extends from the bottom of a tundish 4 into the upstream opening of the mould cavity 3. The mould assemblies 2 are each mounted for rotation on a respective driving roll 6 and idle roll 7. In use, the two mould assemblies are rotated in opposite senses so that the opposed horizontal runs move in the same direction. Molten metal is poured from the tundish 4 through the tundish nozzle 5 into the upstream end of the moving mould cavity 3 and is progressively cooled by the mould blocks 1 and an at least partially solidified casting 8 is discharged from the downstream end thereof. In this casting machine, the cooling zone of each mould assembly 2 is constituted by the return path of the mould assembly between the downstream and upstream ends of the mould cavity 3 and is thus relatively short so that the mould blocks 1 are not sufficiently cooled by the time they return to the upstream end of the mould cavity 3. This results in the risk of failure of the continuous casting operation. To overcome this problem, the inventors have recently proposed a continuous casting machine of the type shown in Figures 2 to 5 in which the cooling zones are of increased length. Figure 2 is a diagrammatic side elevation of the casting machine. Figures 3 and 4 are sectional views on the lines III-III and IV-IV, respectively, in Figure 2 and Figure 5 is a view of a single mould block and its carrier. More specifically, the machine comprises a pair of upper and lower mould assemblies 2, each comprising a plurality of mould blocks 1 connected to form an endless track, disposed in vertically opposed relationship to define the mould cavity 3. The mould assemblies include respective straight runs which diverge by approaching 90° from the downstream end of the mould cavity whereby each mould assembly 2 includes relatively long and inclined horizontal cooling zones 9 and 10 between the downstream and upstream ends of the mould cavity 3, as shown in Figure 2. Each mould assembly 2 is driven by gears 12 and 12′ coupled to a drive system comprising an electric motor 22, a reduction gear 25 and universal spindles 41 (see Figure 3) and is braked at the downstream end of the mould cavity 3 by a gear 13. Such braking of the mould assemblies 2 contributes to preventing melt from leaking through gaps between the mould blocks 1 when they are in the runs defining the mould cavity 3. At the fourth apex of each mould assembly there is a driven gear 11. As shown in Figures 3 to 5, each mould block 1 is securely connected to a carrier 14 which has a rack 15 on each side in mesh with the gears 12 and 13 and has two wheels 16 on each side, as shown in Figure 5. One of the two wheels 16 is directly supported by the carrier 14 by a shaft 17 while the other wheel 16 is indirectly supported by a shaft 17 via a bearing box 19 which is slidably fitted into a groove 18 defined in the carrier 14 and which also supports a further wheel 16 directly supported by an adjacent carrier 14. More specifically, the shaft 17 which is directly supported by the carrier 14 is also mounted in a bearing box 19 which is of the same construction as the bearing box 19 described above and which is slidably fitted into a groove 18 of an adjacent carrier 14. Moreover, the shaft 17 which is directly supported by the said adjacent carrier 14 is also slidably carried by means of a bearing box 19 by the adjacent carrier 14 on the other side. Thus the carriers 14 are sequentially interconnected so that the mould blocks 1 are interconnected in the form of an endless track as described above. The casting machine includes two frames 20 which are disposed on opposite sides of each mould assembly 2 and are formed with an endless groove 21 in which the wheels 16 of the associated mould assembly are rotatably received. The grooves 21 thus act as guide rails for the mould blocks. In Figures 3 and 4, reference numeral 23 represents brakes, 24 represents side dam blocks interposed between opposing mould blocks which are arranged to move in synchronism with the mould blocks and define the side surfaces of the mould cavity, 42 represents the shafts of the gears 12 and 12′ and 43 represents bearings. In operation, the motor 22 is energised to drive the mould blocks 1 through the gears 12 and the racks 15 and the side dam blocks 24 are also driven in synchronism with their associated mould blocks. The brakes 23 are energised to brake the mould assemblies 2 through the gears 13 and the racks 15 so that no gaps are produced between the adjacent mould blocks 1 which define the mould cavity 3. The wheels 16 roll in the grooves 21 so that the mould assemblies 2 are guided and driven smoothly. Melt in the tundish 4 is supplied through the tundish nozzle 5 into the mould cavity 3 and is cooled by the mould blocks to solidify into the casting 8 which is discharged from the casting machine. The mould assemblies 2 are cooled by any means in the cooling zones 9 and 10 and the cooled mould blocks return to the upstream end of the mould cavity 3. As described above, the casting machine shown in Figures 2 to 5 has the cooling zones 9 and 10 which are relatively long so that the mould blocks 1 may be satisfactorily cooled by the time they return to the upstream end of the mould cavity 3 and consequently the continuous casting operation is not adversely affected. In the known continuous casting machines described above, the return path or cooling zone shown in Figure 1 and the horizontal cooling zone 10 shown in Figure 2 have no means to eliminate gaps between the adjacent mould blocks 1 which are passing through these cooling zones, so that a large quantity of cooling liquid leaks through the gaps between the adjacent mould blocks in the cooling zones and this leaked cooling liquid cannot be completely recovered. In addition, the leaked cooling liquid tends to enter the casting machine with various adverse effects. As mentioned above, the brakes 23 are provided to eliminate the gaps between the adjacent mould blocks 1 defining the mould cavity 3 to prevent melt from leaking out of the mould cavity. The motor 22 must thus produce a sufficient driving force to overcome the braking forces of the brakes 23 and thus a large quantity of energy is needlessly consumed. It is therefore an object of the present invention to provide a casting machine of the type referred to above in which the gaps between the adjacent mould blocks defining the mould cavity and preferably also in the cooling zones are eliminated without the use of brakes so that the melt and preferably also the cooling liquid are prevented from leaking through the interfaces between the adjacent mould blocks and the consumption of driving energy is reduced to a minimum. According to the present invention a continuous casting machine of the type referred to above is characterised by an endless member which passes around the shafts of the guide means of each mould assembly and tensioner means arranged to produced a tensile force in the endless member and thus to urge the mould blocks in the associated said run towards one another. Thus, in use, the tensioner means ensures that the mould blocks which define the mould cavity are urged into contact with one another and thus that there are no gaps through which molten metal can escape. In a preferred embodiment of the invention each endless track includes a cooling zone between the downstream and upstream ends of the mould cavity and means for applying cooling fluid to the mould blocks in the cooling zone and passes around guide means at the upstream and downstream ends of the cooling zone and in this embodiment it is preferred that there is an endless member which passes around the shafts of the guide means of each mould assembly and tensioner means arranged to produce a tensile force in the endless member and thus to urge the mould blocks in the cooling zone of each endless track towards one another. In this embodiment the mould blocks in the cooling zone are urged into contact with one another and thus there are no gaps between the mould blocks through which the cooling fluid may escape. The endless member may take several forms but in one embodiment it comprises an endless chain which passes over sprockets mounted on the shafts of the gears and drivingly couples the gears. The tensioner means may also take various forms but in one embodiment includes a sprocket in engagement with the endless chain and a cylinder arranged to displace the sprocket vertically. It is preferred that the sprocket engages that run of the endless chain which is closest to the mould blocks of the associated endless track. The cylinder may be disposed on the side of the endless chain closest to the mould blocks of the associated endless track or remote from them. Further features, details and advantages of the present invention will be apparent from the following description of one preferred embodiment which is given with reference to Figure 6 of the accompanying drawings which is a diagrammatic side elevation of a continuous casting machine in accordance with the invention. The same reference numerals are used to designate similar components throughout the Figures. The casting machine shown in Figure 6 is generally similar to that shown in Figures 2 to 5, but the shafts of the guide means 12, which in this case constitute driven gears, at the upstream end of the mould cavity 3 carry respective sprockets 26 whilst the shafts of the drive means 13, which in this case constitute braked gears at the downstream end of the mould cavity 3 carry respective sprockets 28. It will be appreciated that the guide means, namely the gears 12 and 13, are in positive engagement, that is to say in mesh, with the endless tracks. Each associated pair of sprockets 26,28 is drivingly interconnected by an endless chain 29. Also provided is a tensioner 32 comprising a sprocket 30 in engagement with that run of the endless chain 29 closest to the mould cavity and a vertical actuating cylinder 31 arranged to move the sprocket 30 vertically. Similarly, the gears 11,12′ at the upstream and downstream ends of the horizontal cooling zones 10 are connected to rotate with respective sprockets 33,34 which are drivingly interconnected by an endless chain 35. Again, there is a tensioner 38 comprising a sprocket 36 in engagement with that run of the endless chain 35 closest to the mould asembly 2 and a vertical cylinder 37 arranged to move the sprocket 36 vertically. Reference numeral 39 represents mist coolant devices arranged to cool the mould blocks 1 when they are in the inclined cooling zone 9. Reference numeral 40 represents a liquid coolant chamber arranged to cool the mould blocks 1 when they are in the horizontal cooling zone 10. Continuous casting is carried out in a manner substantially similar to that described above with reference to Figures 2 to 5 and whilst this is taking place the pistons of the cylinders 31 of the tensioners 32 are retracted to produce a tension in the endless chains 29 on the side closest to the associated mould assembly 2. This tension acts on the sprockets 26 and 28 in the directions indicated by the arrows a and b, respectively. As a result, the forces are exerted on the mould blocks 1 defining the mould cavity 3 in the directions indicated by the arrows c and d, respectively, thereby urging adjacent mould blocks into contact so that leakage of melt and intrusion of a cooling liquid past the interfaces between the adjacent mould blocks 1 is actively prevented due to the fact that there are no gaps between the mould blocks. Similarly, the pistons of the cylinders 37 of the tensioner 38 are extended to cause tension in those runs of the endless chains 35 which are closest to the associated mould assembly 2. This results in forces being exerted on the sprockets 34 and 33 in the directions indicated by the arrows e and f, respectively and thus also in forces being exerted on the mould blocks 1 in the horizontal cooling zones 10, in the directions indicated by the arrows g and h, respectively. Any gaps between the adjacent mould blocks 1 are thus eliminated and consequently leakage of the cooling liquid past the interfaces between the adjacent mould blocks is prevented. The tensile forces are therefore utilised to eliminate the gaps between the adjacent mould blocks instead of brakes so that only a relatively low drive power is required and thus the energy consumption to drive the upper and lower mould assemblies 2 is reduced to a minimum.

Claims: A continuous casting machine of endless track type comprising a plurality of mould blocks (1) connected to form two endless tracks (2) having respective runs which cooperate to define a mould cavity (3) and which, in use, are moved in the same direction, each endless track (2) passing around guide means (12,13) at the upstream and downstream ends of the mould cavity (3) characterised by an endless member (29,35) which passes around the shafts of the guide means (12,13,11,12′) of each mould assembly (2) and tensioner means (32,38) arranged to produce a tensile force in the endless member (29) and thus to urge the mould blocks (1) in the associated said run towards one another. A machine as claimed in claim 1 in which each endless track (2) includes a cooling zone (10) between the downstream and upstream ends of the mould cavity (3) and means (40) for applying cooling fluid to the mould blocks (1) in the cooling zone (10) and passes around guide means (11,12′) at the upstream and downstream ends of the cooling zone (10) characterised by an endless member (29,35) which passes around the shafts of the guide means (11,12′,12,13) of each mould assembly (2) and tensioner means (32,38) arranged to produce a tensile force in the endless member (29,35) and thus to urge the mould blocks (1) in the cooling zone (10) of each endless track (2) towards one another. A machine as claimed in claim 1 or claim 2 characterised in that the endless member (29;35) comprises an endless chain which passes over sprockets (26,28;33,34) mounted on the shafts of the gears (12,13;11,12′) and drivingly couples the said gears. A machine as claimed in claim 3 characterised in that the tensioner means (32;38) includes a sprocket (30;36) in engagement with the endless chain (29;35) and a cylinder (31;37) arranged to displace the sprocket (30;36) vertically. A machine as claimed in claim 4 characterised in that the sprocket (30;36) engages that run of the endless chain (29;35) which is closest to the mould blocks (1) of the associated endless track (2). A machine as claimed in claim 4 or claim 5 characterised in that the cylinder (37) is disposed between the endless chain (35) and the mould blocks (1) of the associated endless track (2). A machine as claimed in claim 4 or claim 5 characterised in that the cylinder (31) is situated on the side of the endless chain (29) which is remote from the mould blocks (1) of the associated endless track (2). A machine as claimed in any one of the preceding claims characterised in that the two endless tracks (2) are situated one above the other and the mould cavity (3) extends horizontally and that from the downstream end of the mould cavity (3) each endless track (2) includes a zone (9) extending away from the mould cavity (3) but inclined at an acute angle thereto and thereafter includes a cooling zone (10) extending horizontally.

Inventors: HASEBE, NOBUHISA, OSADA, SHIRO, SATO, HISASHI, TAKAHASHI, SHUZO, TSUCHIDA, YUTAKA
Applicants: ISHIKAWAJIMA-HARIMA  JUKOGYO KABUSHIKI KAISHA, NIPPON KOKAN KABUSHIKI KAISHA
Application year: 1989
Main classification: B22D11
IPC codes: B22D11