Source: http://www.patentgenius.com/patent/6334975.html
Timestamp: 2019-01-22 21:40:55
Document Index: 503974829

Matched Legal Cases: ['art 4', 'art 4', 'art 4', 'art 4', 'art 4', 'art 2', 'art 2', 'art 2', 'art 2', 'art 2', 'art 2', 'art 2', 'art 2']

Molten magnesium supply system - Patent # 6334975 - PatentGenius
Molten magnesium supply system
6334975 Molten magnesium supply system
Application: 09/426,188
Inventors: Katou; Yukio (Kawasaki, JP)
Suzuki; Kazuhiro (Yokohama, JP)
Yokote; Hironori (Ayase, JP)
Assignee: Toshiba Kikai Kabushiki Kaisha (Kawasaki, JP)
U.S. Class: 164/155.2; 222/603; 266/237; 266/94
Field Of Search: 266/94; 266/237; 222/603; 164/155.2
International Class: B22D 17/30
U.S Patent Documents: 5700422
Foreign Patent Documents: 3-37462
Abstract: A molten metal transfer pipe 52 for transferring an injection sleeve 51 has a bent pipe portion 3 thereof reduced in diameter to provide a throttle part 4 attaining a pressure loss effect. A melting and holding furnace 101 with a tilting mechanism has a melting and holding furnace section 101 and an electrical lifter 113 for holding the melting and holding furnace section 101 horizontally and for tilting the melting and holding furnace 101 together with a molten metal supplying apparatus 102 upwardly about the melting chamber 104 serving as a tilting fulcrum C to hold the same in the tilted position. An ingot charging apparatus 201 includes a hood 208 mounted to a conveyor 205 for conveying each preheated magnesium ingot MA, which, at a discharge time of the preheated magnesium ingot MA and at a charge time of the same, communicates with an ingot discharge port 202a of a preheating apparatus 202 and an ingot charge port 203a of a melting and holding furnace 203a to define closed spaces 207 and 206 for allowing a discharge operation of the preheated magnesium ingot MA and a charge operation thereof, and which covers the preheated magnesium ingot MA held by an ingot chuck 204 during conveyance of the preheated magnesium ingot MA.
1. A molten magnesium supply system including:
a molten metal furnace put under a melt level control;
a molten magnesium supplying apparatus comprising
a molten metal transfer pipe communicating at one end thereof with the molten metal furnace, the molten metal transfer pipe having at another end thereof an ascending bent pipe portion as a delivery portion for delivery of molten magnesium to besupplied to an injection sleeve, and
molten metal transferring means for forcing molten magnesium from the molten metal furnace to be transferred in the molten metal transfer pipe and delivered through the delivery portion; and
gas supplying means for supplying an anti-oxidization gas to vacant spaces in the molten metal furnace and the molten metal transfer pipe, wherein
the molten metal transfer pipe is provided with a funnel portion communicating with the delivery portion, for receiving delivered molten magnesium from the delivery portion and supplying received molten magnesium to the injection sleeve.
2. A molten magnesium supply system according to claim 1, wherein the bent pipe portion is reduced to have a throttle part.
a communication part for communication with the bent pipe portion;
a supply hole for supplying received molten magnesium to the injection sleeve; and
a lower part extending between the communication part and the supply hole, the lower part having an inside surface gradually reduced in diameter and smoothly bent between the communication part and the supply hole.
4. A molten magnesium supply system according to claim 3, wherein the supply hole is provided with a shutter therefor.
a first gas supply line for supplying an inert gas as the anti-oxidization gas;
a second gas supply line for supplying a sulfur hexafluoride dilute antideflagrant gas as the anti-oxidization gas; and
control means for supplying a vacant space of the funnel portion with the inert gas when the melt level control to the molten metal furnace is on, and with the sulfur hexafluoride dilute antideflagrant gas when the melt level control is off.
8. A molten magnesium supply system according to claim 7, wherein the control means comprises a control valve operative with a control command for the melt level control.
a melting chamber heated for melting magnesium, and
a holding chamber heated for holding molten magnesium,
the melting chamber communicating with the holding chamber at a bottom region of the crucible member deeper in the melting chamber than in the holding chamber,
the holding chamber communicating with the one end of the molten metal transfer pipe.
13. A molten magnesium supply system according to claim 12, wherein the melting and holding furnace further includes a tilting mechanism for tilting the crucible member together with the molten metal transfer pipe.
the molten metal furnace comprises a melting and holding furnace for melting a preheated magnesium ingot and holding molten magnesium, and
the molten magnesium supply system further comprises ingot charging means for charging the preheated magnesium ingot into the melting and holding furnace, keeping the preheated magnesium ingot substantially free from contact with air.
17. A molten magnesium supply system according to claim 16, wherein
the molten magnesium supply system further comprises a preheater for preheating a magnesium ingot to provide the preheated magnesium ingot in an oxidant-free atmosphere, and
the ingot charging means is adapted for discharging the preheated magnesium ingot from the preheater, keeping the preheated magnesium ingot substantially free from contact with air.
18. A molten magnesium supply system according to claim 17, wherein the ingot charging means is adapted for carrying the preheated magnesium ingot between the preheater and the melting and holding furnace, keeping the preheated magnesium ingotsubstantially free from contact with air.
a chuck for chucking the preheated magnesium ingot;
a carrier for carrying the chuck;
a hood for covering the chuck and the preheated magnesium ingot; and
gas supply means for supplying an anti-oxidization gas inside the hood.
20. A molten magnesium supply system including:
the bent pipe portion is reduced to have a throttle part.
The present invention relates generally to a molten magnesium supply system as well as to a molten magnesium supply method, and in particular, to a molten magnesium supply system that is constituted with a molten magnesium supplying apparatus fora die casting machine of a cold chamber type for casting molten magnesium (with molten magnesium alloy inclusive), or includes a melting and holding furnace for melting a magnesium ingot and holding molten magnesium to be supplied to an injection sleeveof a die casting machine, or an ingot charging apparatus for charging a preheated magnesium ingot into a melting and holding furnace, as well as to a molten magnesium supply method that includes charging a preheated magnesium ingot into a melting andholding furnace, melting the ingot in the furnace, holding molten magnesium in the furnace, and supplying molten magnesium to an injection sleeve of a die casting machine.
Cold-chamber die casting needs fresh and homogeneous molten metal to be continuously and instantaneously injected under high pressure into recesses of a cavity in a mold. For such injection, the die casting machine has an injection sleeve, andis provided with a supply system for supplying molten metal to the injection sleeve. The supply system is adapted for a conforming supply of molten metal meeting various requirements, such as for molten metal amount or quantity to be accurate and natureor quality to be controlled and stable in consideration of molding conditions.
In the case of magnesium, the molten metal has a significant tendency to be oxidized, and needs an air-free supply to the injection sleeve via pipe, duct, etc. For such supply, one may employ a molten metal transfer mechanism or molten metaltransferring means for forcing molten metal to advance in a molten metal transfer pipe. The molten metal transfer mechanism or molten metal transferring means may be of a volume displacement type such as by use of a screw pump, or of a fluid streamingtype such as by use of an electromagnetic pump in which a fluid flow rate is controlled with an electric current in an exciting coil around a fluid circuit.
FIG. 1 illustrates a conventional molten metal supply system. The system comprises a furnace body Fb of a "magnesium melting and/or molten magnesium holding furnace (hereinafter sometimes called "molten metal furnace") 55 and a molten metaltransfer pipe 52 extending therefrom. The transfer pipe 52 is constituted at a suction inlet end thereof with an outlet port Fp of the furnace 55 communicating with an inside of the furnace body Fb, and along the remaining length thereof with a heatedtransfer tube Tb flange-joined to the port Fp. An electromagnetic pump 50 is installed on the inlet end of the pipe 52. The transfer pipe 52 is formed at a delivery end thereof with a downwardly bent portion 52a, which has a downward opening 52b as asupply outlet matching in position with an upward reception opening 51a of an injection sleeve 51.
Molten magnesium M in the molten metal furnace 55 receives a constant leveling, whereby a "surface level of molten magnesium" (hereinafter called "melt level" or simply "level") B in the furnace 55 is controlled so that a melt level A in thetransfer pipe 52, which is equivalent to the level B, is maintained near "a height of a bottom point of an inner circumference at a top of tube wall" (hereinafter sometimes called "delivery height" or simply "height") of the delivery end portion 52a.
In the above-noted system, molten magnesium M flowing in the pipe 52 is subjected to a flow resistance at both suction and delivery sides of the electromagnetic pump 50. The flow resistance of pipe 52 is small, but increases with foreignmaterials sticking on the wall or mixed in metal. In this case, if the coil current of the pump 50 is constant, the pump 50 delivers a reduced amount of molten metal.
To keep the delivery rate free from unfavorable influences of conditions in the transfer pipe 52, a throttle 53 is installed at a flange joint portion 52d of the pipe 52, and fixed thereto. The throttle 53 provides a sufficient flow resistancefor the pump 50 to deliver a corresponding flow rate of molten metal, allowing for the transfer pipe 52 to supply the flow rate of molten metal.
In order to prevent molten magnesium M from being oxidized, an injection opening 52c for injecting anti-oxidization gas G for the molten magnesium M is provided at a top portion of the delivery end portion 52a. Anti-oxidization gas G injectedfrom the injection opening 52c is filled in a space defined by molten metal of the melt level A and the wall of to the delivery end portion 52a of the transfer pipe 52, so that molten metal M to be supplied to the injection sleeve 51 is prevented fromoxidization. The anti-oxidization gas G is also injected in the molten metal furnace 55, and a space above the melt level B in the furnace 55 is filled with the gas G.
As the anti-oxidization gas G, there is used a diluted antideflagrant gas in which sulfur hexafluoride (hereinafter referred to as "SF.sub.6 ") is diluted with dried air, or an inert gas such as argon.
In FIG. 1, reference numeral 54 denotes a heater, reference numeral 57 denotes an injection plunger driven in a reciprocating manner within the injection sleeve 51 by a hydraulic operation mechanism 58, and reference numeral 59 denotes a metalmold cavity communicating with the injection sleeve 51.
In the conventional molten metal supply system empolying an electromagnetic pump, however, as the throttle 53 is fixed to the flange joint portion 52d of the transfer pipe 52, there occur needs of pipe disconnection for maintenance services, suchas for cleaning to the throttle 53 or pipe wall therearound or for replacement of the throttle 53. In particular, in the case of molten magnesium (including molten magnesium alloy), the molten metal tends to be oxidized or combusted during such aservice.
Though one of SF.sub.6 dilute antideflagrant gas and an inert gas such as argon is generally used as anti-oxidization gas G, such a use of single gas has a potential possibility of causing molten metal oxidization or loose ending or cut of moltenmetal supply. There is a problem of increased oxidization, followed by difficulty in maintenance work, and a supply amount of molten metal becomes unstable, so that a stable die casting work can not be performed.
That is, SF.sub.6 dilute antideflagrant gas is relatively inexpensive and has a high antideflagrant effect owing to a high dilution rate thereof. However, when molten magnesium M is transferred to the injection sleeve 51 by the electromagneticpump 50, oxidization of the molten magnesium M and/or reaction product is easy to occur and the ending of molten magnesium supply at the opening 52b of the delivery end portion 52a becomes sharp.
An inert gas such as argon is used alone, which becomes relatively expensive, however, oxidization of the molten magnesium M is reduced and the ending of molten magnesium supply is improved. In an ordinary use, however, the antideflagrant natureis relatively inferior, and there is a problem that, when the melt level M in the molten metal furnace 55 varies at an ON/OFF time of the constant melt level control and external air enters in/leaves from the molten metal furnace 55, the molten magnesiumM sticking on an inner surface of the delivery end portion 52a is oxidized.
Furthermore, in the conventional molten metal supply system empolying an electromagnetic pump, as the delivery end portion 52a of the transfer pipe 52 is bent downwards, delivered molten magnesium M falls into the injection sleeve 51, where ithas turbulent streams. Turbulent streams accompany air inclusion into molten metal M, causing oxidization and combustion of molten magnesium M, with an increased quantity of reaction products such as oxides, constituting a difficulty of maintenance,rendering supply molten metal amount unstable. As a result, a stable die casting work can not be obtained.
Also, in a conventional melting and holding furnace, a crucible having a bath tab shape is partitioned into a melting chamber and a holding chamber by a partition plate. In this case, the melting chamber is cold-charged (ingot is thrown andmelted in the melting chamber) and molten magnesium is transferred to the holding chamber via the partition plate. A transfer pipe is provided downward of the holding chamber, and molten magnesium is filled in the transfer pipe.
In Japanese Patent Publication No. 3-37462, there has been disclosed a temperature holding furnace provide with a transfer pipe for supplying molten metal to an injection sleeve in a die casting machine. The temperature holding furnace has astructure in which molten metal is hot-charged from another melting furnace, and the furnace itself is maintained horizontally during die casting work and it is maintained together with the transfer pipe in its tilted position during stopping of diecasting work.
In these cases, when the molten metal to be applied is magnesium alloy, as it has a tendency to rapidly produce oxide with air in contact, oxidization of the metal can be suppressed in a state in which a space in the transfer pipe is filled withantideflagrant gas, which results in improvement in quality of die cast product.
In the latter temperature holding furnace, molten metal in the transfer pipe can be transferred by holding the temperature holding furnace as well as the transfer pipe in the tilted position so that easiness in such a work as maintenance can beachieved. In the conventional melting and holding furnace or temperature holding furnace, however, when a cold charge or a hot charge is conducted, disturbance occurs in molten magnesium portion around charged portion, air is involved in moltenmagnesium due to this disturbance, and the molten magnesium is oxidized, so that much dross/sludge occurs due to this oxidization. There is a drawback that, since molten magnesium including this dross/sludge is transferred to the transfer pipe portionvia the holding chamber, which results in troubles inside the transfer pipe and/or bad quality products.
Also, in the conventional melting and holding furnace, as the transfer pipe is fixed in a horizontal position, when it is required to discharge molten magnesium contained in the transfer pipe at a time of maintenance or the like, it is not onlymade impossible to discharge molten magnesium remaining in the transfer pipe completely but also it is required to handle some molten magnesium sufficiently carefully, which results in difficulty in maintenance work.
Furthermore, in the melting and holding furnace, as one crucible serves as the melting chamber and the holding chamber, there are two cases, namely cold charge is being effected in the melting chamber side and it is not being effected. Due tothese two cases, there occurs a drawback that, when the temperature of the molten magnesium in the holding chamber is controlled, it becomes difficult to maintain molten magnesium in the holding chamber in a constant temperature without temperaturevariation, and fluidic characteristic of molten magnesium varies due to temperature variation so that supply amount of molten magnesium is made unstable and, therefore, die cast products of a good quality can not be secured in a stable manner.
A first conventional method or a second conventional method is employed for charging a magnesium ingot to a melting and holding furnace. In the first conventional method, a rack for preheating is placed on a melting and holding furnace and amagnesium ingot is manually thrown into molten magnesium. In the second conventional method, when a preheated magnesium ingot placed with a lying position in which its longitudinal axis is horizontal is automatically charged from a preheating apparatusto a melting and holding furnace, it is pushed on such guide means as a rolling type conveyor and thrown by a cylinder so as to fall in the melting and holding furnace.
In the first conventional method, a degree of freedom for throwing is high to some extent, but first a worker is always required therefor and secondly a furnace lid can not be put in an opened state for a long time in view of radiation heat fromthe melting and holding furnace and/or oxidization of molten magnesium.
In the first and second conventional methods, thus, generation of dross/sludge is increased due to the disturbances of the molten magnesium melt level and the antideflagrant gas atmosphere, so that a problem or defect occurs in the quality of diecast products obtained.
When the furnace lid is opened for a long time, the temperature of molten magnesium is lowered and, when die casting is performed in a die casting machine, fluidity of molten magnesium deteriorates and varies due to the temperature lowering. Asa result, a problem or defect occurs in the quality of die cast products.
Furthermore, a variation of melt level corresponding to one magnesium ingot and acceleration of vertical movement of melt surface due to falling of a magnesium ingot with nonstop acts as dynamic pressure variation in a molten metal transfer pipe,for example, in a molten magnesium supply system employing an electromagnetic pump. There are also a drawback in which the dynamic pressure in the transfer pipe adversely affects metering accuracy for the delivery amount of molten magnesium.
A first object of the present invention is to provide a molten magnesium supply system including a molten magnesium supplying apparatus which has an excellent easiness in maintenance work or in which the supply amount of molten magnesium is madestable so that a stable die casting work can be obtained.
A second object of the invention is to provide a molten magnesium supply system including a melting and holding furnace with a tilting mechanism in which maintenance work can be made easy and dross/sludge occurring in a melting chamber can beeffectively prevented from moving to a holding chamber, and temperature of molten magnesium in the holding chamber can be controlled with a high accuracy, so that die cast products of a good quality can be obtained in a stable manner.
A third object of the invention is to provide a molten magnesium supply system including an ingot charging apparatus, and a molten magnesium supply method in which automatic charge of a magnesium ingot is allowed in a state in which oxidizationof molten magnesium, temperature lowering of the molten magnesium and melt level variation are suppressed to the utmost, thereby improving and stabilizing the quality of die cast product.
To achieve objects, an aspect of the present invention provides a molten magnesium supply system including a molten metal furnace put under a melt level control, a molten magnesium supplying apparatus comprising a molten metal transfer pipecommunicating at one end thereof with the molten metal furnace, the molten metal transfer pipe having at another end thereof an ascending bent pipe portion as a deliver) portion for delivery of molten magnesium to be supplied to an injection sleeve, andmolten metal transferring means for forcing molten magnesium from the molten metal furnace to be transferred in the molten metal transfer pipe and delivered through the delivery portion, and gas supplying means for supplying an anti-oxidization gas tovacant spaces in the molten metal furnace and the molten metal transfer pipe, wherein the molten metal transfer pipe is provided with a funnel portion communicating with the delivery portion, for receiving delivered molten magnesium from the deliveryportion and supplying received molten magnesium to the injection sleeve.
According to this aspect, a melt level of molten magnesium in a molten metal transfer pipe is maintained at a delivery height of a bent pipe portion close to a funnel portion according to a melt level control in a molten metal furnace. Moltenmagnesium is delivered from a delivery portion of the molten metal transfer pipe to the funnel portion, as it is forced to be transferred by molten metal transferring means, and delivered molten magnesium is wholly supplied to an injection sleeve.
In a molten magnesium supply system according to any applicable aspect herein, the funnel portion may preferably comprise a communication part for communication with the bent pipe portion, a supply hole for supplying received molten magnesium tothe injection sleeve, and a lower part extending between the communication part and the supply hole, the lower part having an inside surface gradually reduced in diameter and smoothly bent between the communication part and the supply hole.
In this case, a melt level of molten magnesium in a molten metal transfer pipe is maintained at a delivery height of a bent pipe portion according to constant melt level control in a molten metal furnace, close to a funnel portion. Moltenmagnesium is delivered from a delivery end of the molten metal transfer pipe to the funnel portion by molten metal transferring means and the whole delivered amount of molten magnesium is supplied to an injection sleeve.
Since supplying molten magnesium to the injection sleeve is performed from the melt level of molten magnesium close to a supply hole of the funnel portion, a flowing-out head of the molten magnesium can be made small. Since the inside surface ofa lower part of the funnel portion is gradually reduced in inside diameter and bent smoothly, it is formed in a smooth flowing-out sloped surface and molten magnesium is supplied to the injection sleeve in a turbulence-reduced state. Accordingly,oxidization of the molten magnesium and reaction product therewith are prevented from occurring at the supply end and troubles such as combustion, blocking, staying, and the like due to such an occurrence are also prevented, so that molten metal supplyto the injection sleeve can be sharply ended. Thus, the molten magnesium supplying apparatus has an excellent easiness in maintenance work, and a supply amount of molten magnesium is made stable so that a stable die casting work can be performed.
In this case, the lid can be attached to or detached from an upper opening of the funnel portion, permitting a facilitated maintenance and cleaning to the funnel portion, allowing an improved maintenance service and a stable supply of moltenmagnesium.
In a molten magnesium supply system according to any applicable aspect herein, the gas supply means may preferably comprise a first gas supply line for supplying an inert gas as the anti-oxidization gas, a second gas supply line for supplying asulfur hexafluoride dilute antideflagrant gas as the anti-oxidization gas, and control means for supplying a vacant space of the funnel portion with the inert gas when the melt level control to the molten metal furnace is on, and with the sulfurhexafluoride dilute antideflagrant gas when the melt level control is off.
In this case, a melt level of molten magnesium within a molten metal transfer pipe is maintained at a delivery height of a bent pipe portion and close to a funnel portion. An amount of molten magnesium is transferred by the molten metaltransferring means, and is delivered from the delivery portion of the molten metal transfer pipe to the funnel portion so that delivered molten magnesium is wholly supplied to an injection sleeve.
When the melt level control to the molten metal furnace is turned on, an inert gas is filled in a vacant space of the funnel portion, whereby the delivered molten magnesium is kept from oxidization and in free of reaction products due to suchoxidization, thus allowing the ending of molten magnesium supply to be quick and sharp, so that supply of molten magnesium to the injection sleeve is rendered stable.
When the melt level control is turned off at the molten metal furnace, a sulfur hexafluoride dilute antideflagrant gas is filled in a vacant space that the funnel portion then has, so that oxidization and combustion of molten magnesium isprevented over an off-duty period of molten magnesium supply, and molten magnesium left in the transfer pipe is kept free from magnesium oxides that otherwise might have been produced by such oxidization or combustion. Such oxides would have adhered toor deposited on the wall of the transfer pipe. As a result, molten magnesium supply is allowed to be ended sharp. Maintenance to the system is facilitated. A necessary supply amount of molten magnesium is secured, ensuring a conforming die casting.
In a molten magnesium supply system according to any applicable aspect herein, the molten metal furnace may preferably comprise a melting and holding furnace including a crucible member provided with a melting chamber heated for melting magnesiumand a holding chamber heated for holding molten magnesium, the melting chamber communicating with the holding chamber at a bottom region of the crucible member deeper in the melting chamber than in the holding chamber, the holding chamber communicatingwith the one end of the molten metal transfer pipe.
In this case, a cold-charged magnesium block may be melted in a melting chamber. Streams of heavier molten magnesium tend to be stagnant at a bottom of the melting chamber, where they are advantageously kept from flowing through a holdingchamber into the molten metal transfer pipe.
In a molten magnesium supply system according to any applicable aspect herein, the molten metal furnace may preferably comprise a melting and holding furnace for melting a preheated magnesium ingot and holding molten magnesium, and the moltenmagnesium supply system may preferably comprise ingot charging means for charging the preheated magnesium ingot into the melting and holding furnace, keeping the preheated magnesium ingot substantially free from contact with air.
In a molten magnesium supply system according to any applicable aspect herein, the molten magnesium supply system may preferably comprise a preheater for preheating a magnesium ingot to provide the preheated magnesium ingot in an oxidant-freeatmosphere, and the ingot charging means may preferably be adapted for discharging the preheated magnesium ingot from the prehater, keeping the preheated magnesium ingot substantially free from contact with air.
In a molten magnesium supply system according to any applicable aspect herein, the ingot charging means may preferably be adapted for carrying the preheated magnesium ingot between the preheater and the melting and holding furnace, keeping thepreheated magnesium ingot substantially free from contact with air.
In a molten magnesium supply system according to any applicable aspect herein, the ingot charging means may preferably comprise a chuck for chucking the preheated magnesium ingot, a carrier for carrying the chuck, a hood for covering the chuckand the preheated magnesium ingot, and gas supply means for supplying an anti-oxidization gas inside the hood.
Further, to achieve the first aspect, another aspect of the invention provides a molten magnesium supply system including a molten metal furnace put under a melt level control, a molten magnesium supplying apparatus comprising a molten metaltransfer pipe communicating at one end thereof with the molten metal furnace, the molten metal transfer pipe having at another end thereof an ascending bent pipe portion as a delivery portion for delivery of molten magnesium to be supplied to aninjection sleeve, and molten metal transferring means for forcing molten magnesium from the molten metal furnace to be transferred in the molten metal transfer pipe and delivered through the delivery portion, and gas supplying means for supplying ananti-oxidization gas to vacant spaces in the molten metal furnace and the molten metal transfer pipe, wherein the bent pipe portion is reduced to have a throttle part.
According to this aspect, upon delivery of molten magnesium from a delivery portion that is an ascending bent pipe portion of a molten metal transfer pipe, molten magnesium flowing in bent pipe portion is subjected to a flow resistance of athrottle part, having a head loss developed thereacross. As the flow resistance can be set in a voluntary manner, the head loss can be large enough to substantially control delivery rate of molten magnesium without employing a conventional throttlefixed to a flange joint portion at a suction end.
To achieve the second object, another aspect of the invention provides a molten magnesium supply system including a melting and holding furnace with a tilting mechanism comprising a melting and holding furnace section constituted with a cruciblewhose interior is partitioned to a holding chamber and a melting chamber by a partition portion such that molten magnesium is mutually movable between the holding chamber and the melting chamber, the bottom portion of the melting chamber being lower thanthe bottom portion of the holding chamber, and heating means being respectively provided for heating the holding chamber and the melting chamber exclusively, a molten metal supplying apparatus provided so as to communicate with the holding chamber, forsupplying molten magnesium into an injection sleeve of a die casting machine, and a tilting mechanism for holding the melting and holding furnace section horizontally and for, as occasion demands, tilting the melting and holding furnace section togetherwith the molten metal supplying apparatus upwardly about the melting chamber serving as a tilting fulcrum to hold the same in the tilted position.
According to this aspect, dross/sludge generated in a melting furnace and/or molten magnesium with a relatively high specific gravity which has just been cold-charged to melt down are deposited or stayed on a bottom of the melting chamber due toa difference in height between a bottom portion of a holding chamber and the bottom portion of the melting chamber and they can be prevented from moving the holding chamber.
Also, respective temperature controls of molten magnesium respectively contained in the holding chamber and the melting chamber can be performed by respective exclusive heating means regardless of temperatures of the molten magnesium in therespective adjacent chambers. Accordingly, the temperature control of molten magnesium in the holding chamber can be performed with a high accuracy by the exclusive heating means regardless of absence/existence of cold-charge, and die cast products agood quality of can be obtained in a stable manner.
In a molten magnesium supply system according to the above aspect, the holding chamber may preferably be formed at the bottom portion thereof in an approximate flat bottom, the melting chamber may preferably be extended from the approximate flatbottom and formed in a downwardly concave round bottom, and the heating means may preferably be constituted with an electric heater for the holding chamber and a gas burner for the melting chamber.
In this case, dross/sludge generated in a melting chamber and/or molten magnesium with a relatively high specific gravity, as it has just been molten from a cold-charged block, are stayed or deposited in a round bottom of a melting chamber owingto a difference in shape between a bottom of a holding chamber and the melting chamber, so that they are kept from being carried into the holding chamber.
Temperature of molten magnesium in the holding chamber can be controlled with a high accuracy by a readily controllable electric heater, and magnesium ingot charged to the melting chamber can melt in a short while with an efficient hot heating ofthe round bottom by a gas burner. Accordingly, die cast products can be obtained with a secured quality.
As the bottom of the melting chamber is shaped in a round form, melting work in which supply of molten magnesium is not performed can be effected with a position of the melting and holding furnace held in an inclination state, so thatdross/sludge generated during melting work and molten magnesium having a relatively high specific gravity which has just been melted down can almost completely be prevented from being transferring to the holding chamber. Accordingly, troubles which mayoccur in an interior of a molten metal supplying apparatus are suppressed so that maintenance work can be facilitated and die cast products of a good quality can be obtained in a more stable manner.
To achieve the third object, another aspect of the invention provides a molten magnesium supply system including an ingot charging apparatus for charging a preheated ingot from a preheating apparatus to a melting and holding furnace, the systemcomprising conveying means for holding the preheated magnesium ingot by an ingot chuck to discharge the same from the preheating apparatus and for conveying the discharged magnesium ingot to charge the same into the melting and holding furnace, and ahood mounted to the conveying means, which communicates with an ingot discharge port of the preheating apparatus and an ingot charge port of the melting and holding furnace respectively at an ingot discharge time and at an ingot charge time of thepreheated magnesium ingot to form closed spaces for allowing ingot discharge operation of the ingot chuck and allowing charge operation thereof, and which covers the preheated magnesium ingot held by the ingot chuck during conveyance.
As discharge of the preheated ingot from the preheating apparatus and charge thereof to the melting and holding furnace are performed by an ingot chuck operated within closed spaces defined by a hood, immersion of air, disturbance or flowing-outof antideflagrant gas in the melting and holding furnace and heat dissipation form the melting and holding furnace can be suppressed.
As the preheated magnesium ingot is covered with the hood during conveyance from the preheating apparatus to the melting and holding furnace, heat dissipation from the magnesium ingot is suppressed and temperature lowering of the ingot itself canbe suppressed to the utmost. By the provision of an ingot charging apparatus, a preheated magnesium ingot can automatically be charged to the melting and holding furnace, so that oxidization of molten magnesium, temperature lowering of the moltenmagnesium, and variation in molten surface are suppressed to the utmost. As a result, the ingot charging apparatus contributes to an improvement in quality of die cast products, allowing for a secured quality.
In this case, charge of a preheated magnesium ingot to a melting and holding furnace can be carried out while antideflagrant gas is injected into a closed space defined by a hood. Oxidization of molten magnesium is suppressed by injection of theantideflagrant gas, allowing a decrease in charge speed of the ingot. Corresponding to the decrease, variations in molten magnesium temperature and/or disturbances of molten magnesium melt level and of antideflagrant gas atmosphere can be suppressed. Accordingly, die cast products can be improved with a secured quality.
To achieve the third object, another aspect of the invention provides a molten magnesium supply method including charging a preheated magnesium ingot by using an ingot charging apparatus according to the above aspect, wherein the preheatedmagnesium ingot is held by the ingot chuck in a longitudinal position where its longitudinal axis is vertical to be discharged from the preheating apparatus by the conveying means and to be conveyed to the melting and holding furnace, and, after mostportion of the magnesium ingot is immersed in molten magnesium in the melting and holding furnace by a vertical downward operation of the ingot chuck at a low speed in a state in which the closed space defined by the hood communicating with the ingotcharge port of the melting and holding furnace is filled with the antideflagrant gas injected from the gas injection port, the magnesium ingot is released into the melting and holding furnace.
According to this aspect, as a preheated magnesium ingot can enter in a melting and holding furnace from an ingot charge port in a longitudinal position where its longitudinal axis is vertical, the ingot charge port can be set such that itsopening area is small, and correspondingly heat dissipation from the melting and holding furnace can be suppressed.
Immersion of the preheated magnesium ingot to molten magnesium is carried out by vertical downward operation of an ingot chuck at a low speed in a state in which a closed space is filled with antideflagrant gas, namely the immersion can beperformed in a state in which oxidization of molten magnesium, variation in molten magnesium temperature, and disturbances of a molten magnesium melt level and a antideflagrant gas atmosphere are suppressed. Accordingly, an ingot charging method can beprovided to improve and stabilize quality of die cast products.
Another aspect of the invention provides a molten magnesium supply method comprising the steps of chucking a preheated magnesium ingot in a suspended position, keeping the chucked magnesium ingot free from contact with air, charging the chuckedmagnesium ingot into a crucible communicating with a molten metal transfer pipe and controlled for a melt level of molten magnesium therein, transferring molten magnesium to be delivered from the crucible through the transfer pipe and supplied to aninjection sleeve before a shot of supplied molten magnesium for a die casting, lowering the chucked magnesium ingot to be partially dipped and melted in molten magnesium in the crucible, as the melt level is lowered, repeating the transferring moltenmagnesium, repeating the lowering the chucked magnesium ingot, and releasing the dipped magnesium ingot into molten magnesium in the crucible.
FIGS. 5A and 5B are schematic explanatory views illustrating a portion of a molten magnesium supplying apparatus according to a third embodiment of the invention, in which FIG. 5A and 5B respectively illustrate supplying states of differentanti-oxidization gases;
FIGS. 6A and 6B are schematic explanatory views illustrating a portion of a molten magnesium supplying apparatus according to a modified third embodiment of the invention, in which FIG. 6A and 6B respectively illustrate supplying states ofdifferent anti-oxidization gases;
FIG. 2 is a schematic explanatory view illustrating a schematic entire configuration of a molten magnesium supplying apparatus I according to an embodiment of the invention. The molten magnesium supplying apparatus 1 is applied to a cold chamberdie casting machine which effects die casting for molten magnesium (including magnesium alloy). The apparatus 1 includes an electromagnetic pump 50 serving as molten metal transferring means, and a suction side of the electromagnetic pump 50communicates with a molten metal furnace 55 subjected to constant melt level control while a molten metal transfer pipe 52 formed at its delivery side in a bent pipe portion 3 bent upward and communicating with a funnel portion 2 is provided at adelivery side of the pump 50. In a state in which anti-oxidization gas G is filled in the funnel portion 2, the electromagnetic pump 50 is driven to supply molten magnesium M within the molten metal furnace 55 into an injection sleeve 51 through themolten metal transfer pipe 52 and the funnel portion 2. The molten magnesium supplying apparatus 1 is structured as mentioned above.
The bent pipe portion 3 has a structure in which its distal end portion is bent in a standing manner at an angle of about 45 degrees from a horizontal direction obliquely and upwardly and an upper end thereof is connected to the funnel portion 2,and a heater 54 is disposed of outside the bent pipe portion 3. The bent pipe portion 3 can be heated by the heater 54 so as to be kept at a constant temperature.
Molten magnesium transferred by the electromagnetic pump 50 is delivered from a delivery end of the molten metal transfer pipe 52 to the funnel portion 2 and the total amount of the molten magnesium delivered is supplied to the injection sleeve51. At this time, since the electromagnetic pump 50 is employed as the molten metal transferring means, transferring of molten magnesium M performed by driving of the electromagnetic pump 50 can be automatically controlled in an interlocking manner withconstant melt level control and supply of anti-oxidization gas G.
Incidentally, in the molten magnesium supplying apparatus 1, pumping drive of the electromagnetic pump 50 is interlocked with the constant melt level control. Delivery operation of molten magnesium M is performed during the constant melt levelcontrol to effect operation of the die casting machine and to produce a product, while molten magnesium M is returned back to the molten metal furnace 55 and operation of the die casting machine and production of a product are stopped during a constantmelt level non-control state in which the constant melt level control is out of duty.
The molten magnesium supplying apparatus 1 thus constituted is further constituted as a first embodiment illustrated in FIG. 3, a second embodiment illustrated in FIG. 4, a third embodiment illustrated in FIGS. 5A and 5B, and a fourth embodimentillustrated in FIGS. 6A and 6B.
As shown in FIG. 3, the first embodiment is constituted with a throttle part 4 formed at a portion of the bent pipe portion 3 of the molten metal transfer pipe 52 by reducing the diameter of the portion. The throttle part 4 is formed a portionof the bent pipe portion 3 close to the funnel portion 2, and it is provided, for example, by machining the portion to reduce the diameter of the bent pipe portion 3 itself or by welding a machined pipe to the bent pipe portion 3.
In this embodiment, when molten magnesium M is supplied to the injection sleeve 51, it passes through the throttle part 4. At a time of the passing-through of the molten magnesium M, the throttle part 4 can develop the same pressure effect asthat of a conventional fixed throttle and a supply amount of molten magnesium is made stable, which results in a stable die casting work.
That is, the funnel portion 2 is opened at its upper part 2b to the injection sleeve 51 and is opened at its lower part serving as a delivery opening 2a and, thus, the entire shape thereof is formed in a funnel shape. The upper part 2b iscovered with a attachable/detachable lid 5 and the lower part is closed by a shutter 6 such that it can be opened/closed. At this time, as the lid 5 is merely put on the upper part 2b to cover the opening thereof, it can easily be detached, andmaintenance and cleaning works of the funnel portion 2 and portions around the same can easily be carried out through the opening of the upper part 2b of the funnel portion 2 by detaching the lid 5.
Incidentally, the shutter 6 is provided so as to be opened in an interlocking manner with operation of the electromagnetic pump 50 only at a time of delivery of molten magnesium M. Furthermore, the funnel portion 2 does not require an outsideheater necessarily and it is normally constituted without the heater in view of simplification of its structure.
As illustrated in FIG. 4, the second embodiment is structured such that a lower side portion 2c of the funnel portion 2 extending from a communication part 2d with the bent pipe portion 2 to the delivery opening 2a to the injection sleeve 51 hasan inside surface 2e which is gradually reduced in inside diameter from the communication part 2d towards the delivery opening 2a and is bent smoothly.
For example, the inside surface 2e has a curved line which is sloped from the communication part 2d as an origin downwardly at an angle of about 40 degrees and in which the inclination angle .theta. increases continuously towards the lower sideportion 2c within 90 degrees, and it is constituted as a curved face obtained by rotating the curved line about an axial line C passing through the center of the delivery opening 2a.
The funnel portion 2 is formed in a funnel shape as a whole, and is structured in a similar manner to the first embodiment by causing the upper end of the bent pipe portion 3 to communicate with a boundary portion between a cylindrical funnelupper part and a funnel lower part having a gradually reduced diameter. This funnel portion 2 is formed of, for example, a plate material of iron system having a thickness of 2 mm or less, and aluminizing processing is effected on a surface (an insidesurface) of the formed funnel portion 2 and further a secondary diffusion processing is performed on the aluminized funnel portion 2.
In this second embodiment, as supplying molten magnesium to the injection sleeve 51 is carried out from the molten magnesium melt level A close to the delivery opening 2a of the funnel portion 2, a falling-down head of molten magnesium M can bereduced. Also, as the inside surface 2e of the lower part 2c of the funnel portion 2 is formed in a smooth flowing-out sloped surface having an angle of about 40 degrees or more, the molten magnesium M is supplied to the injection sleeve 51 in a lessturbulence condition.
According to the second embodiment, therefore, oxidization of the molten magnesium M and reaction product at a delivery end (the delivery opening 2a) are prevented from occurring, such a trouble as combustion, blocking, staying or the like due tooccurrences of the oxidization and the reaction product is prevented from occurring. Also, molten magnesium supply can be ended in an excellent state, so that a high working easiness can be obtained in maintenance and supply of molten magnesium is madestable, which results in a stable die casting work.
Furthermore, as illustrated in FIGS. 5A, 5B, 6A and 6B, the third and the fourth embodiment is constituted such that anti-oxidization gas G includes gases of two different kinds of inert gas G1 and SF.sub.6 dilute antideflagrant gas G2, and theinert gas G1 and the SF.sub.6 dilute antideflagrant gas G2 supplied from gas supply lines 7 and 8 of two systems are respectively supplied to the funnel portion 2 at the constant melt level control time and the constant melt level non-control time.
At this time, the second embodiment is preferably constituted such that supply of SF.sub.6 dilute antideflagrant gas G2 is controlled by a control valve 10 operated according to ON/OFF signals for controlling the constant melting face in themolten metal furnace 55.
In the third embodiment, the gas supply lines 7, 8 of two system are connected at their gas injecting ends 7a, 8a to an upper side wall of the funnel portion 2 through the control valve 10 (refer to FIGS. 5A, 5B), or respective gas injection endsof the gas supply lines 7, 8 are combined in one gas injection end 9 which is connected to an upper side wall of the funnel portion 2 (refer to FIGS. 6A, 6B). The gas injection ends 7a, 8a (or gas injection end 9) are easily connected to the funnelportion 2, as the funnel portion 2 is constituted without any heater. Also, as the connection is performed apart from the lid 5, opening/closing work of the lid 5 can easily be conducted at a time of maintenance.
The control valve 10 thus mounted causes the gas supply line 7 and the gas injection end 7a to communicate with each other (refer to FIG. 5), or it causes the gas supply line 7 and the gas injection end 9 to communicate with each other (refer toFIG. 6A), via its port `a` by input of ON signal for controlling the constant melt level at a supply time of molten magnesium, while the control valve 10 causes the gas supply line 8 and the gas injection end 8a to communicate with each other (refer toFIG. 5B), or it causes the gas supply line 8 and the gas injection end 9 (refer to FIG. 6B), via its port b by input of OFF signal for stopping the constant melt level at a non-supply time of molten magnesium. Thereby, the funnel portion 2 is filledwith the inert gas G1 supplied thereto from the gas supply line 7 at the supply time of molten magnesium (refer to FIGS. 5A and 6A), while it is filled with the SF.sub.6 dilute antideflagrant gas G2 supplied thereto from the gas supply line 8 at anon-supply time of the molten magnesium (refer to FIGS. 5B and 6B).
That is, when the constant melt level control is turned ON, after time delay lapsing until the melt level A of the molten magnesium M in the molten metal transfer pipe 52 reaches a holding level is estimated, supply of only the inert gas G1 iseffected, while supply of only the SF.sub.6 dilute antideflagrant gas G2 is effected immediately after the constant melt level control is turned OFF.
According to the third embodiment, the inert gas G1 is filled in the funnel portion 2 at a time of the constant melt level control on the molten metal furnace 55, so that occurrence of oxidization of magnesium M and reaction product is suppressedand molten magnesium to the injection sleeve 51.
Also, at a constant melt level non-control on the molten metal furnace 55, the SF.sub.6 dilute antideflagrant gas G2 is filled in the funnel portion 2, so that occurrence of oxidization of magnesium M and reaction product can be suppressed atthis time.
Thus, in the third embodiment, as occurrence of oxidization of magnesium M and reaction product can be suppressed both at the supply time of molten magnesium and the non-supply time to the injection sleeve 51 thereof, attaching of magnesium oxideon an apparatus inner wall and/or deposition thereof on a bottom portion of the apparatus are reduced and molten magnesium supply can be ended in an excellent state. Accordingly, an excellent working easiness can be obtained in maintenance and a supplyamount of molten magnesium is made stable, which results in a stable die casting work.
Incidentally, the SF.sub.6 dilute antideflagrant gas G2 which is relatively inexpensive and which has an antideflagrant effect larger than that of inert gas is supplied to the molten metal furnace 55 as the anti-oxidization gas G (refer to FIG.2).
The molten magnesium supplying apparatus of the present invention is not limited to only the embodiments, but it includes a combination of the first and second embodiments, a combination of the second and third embodiments, and a combination ofthe first to third embodiments. Each combination provides further easiness in maintenance work and provides more stable molten magnesium supply.
The electromagnetic pump 50 serving as a fluid streaming type transfer mechanism may be substituted with another molten magnesium transfer mechanism or means of a fluid streaming type, or may preferably be replaced by a molten magnesium transfermechanism of means of a volume replacement type, such a screw pump, a metal pump, etc.
This melting and holding furnace 101 with a tilting mechanism comprises a melting and holding furnace section 101 constituted with a crucible 130 whose interior is partitioned to a holding chamber 103 and a melting chamber 104 by a partitionportion 105 such that molten magnesium M is mutually movable between the holding chamber 103 and the melting chamber 104, the bottom portion 104a of the melting chamber 104 being lower than the bottom portion 103a of the holding chamber 103, and heatingmeans 8, 9 being respectively provided for heating the holding chamber 103 and the melting chamber 104 exclusively;
a tilting mechanism 113 for holding the melting and holding furnace section 101 horizontally and for, as occasion demands, tilting the melting and holding furnace 101 together with the molten metal supplying apparatus 102 upwardly about themelting chamber 104 serving as a tilting fulcrum C to hold the same in the tilted position.
The melting and holding furnace section 101 is closed at an upper opening of the crucible 130 extending over the holding chamber 103 and the melting chamber 104 by a furnace lid 110, and a space between the furnace lid 110 and a melt level A ofmolten magnesium M received inside the holding chamber 103 and the melting chamber 104 is filled with antideflagrant gas. The antideflagrant gas is filled in both spaces of the holding chamber 103 and melting chamber 104. An ingot charging lid 110a isprovided at a portion of the furnace lid 110 which corresponds to the melting chamber 104 and which is spaced from the holding chamber 103 as far as possible such that it can be opened/closed. Magnesium ingot (not shown) can be charged to the meltingchamber 104 through the opened ingot charging lid 110a.
A melt level level 111 is disposed in the holding chamber 103 in a floating manner on melt level A. Charging of magnesium ingot is controlled or managed by the melt level level 111 such that melt level is constant. Molten magnesium M ormagnesium ingot melted moves through the partition portion 105 to the holding chamber 103.
The melting chamber 104 has the bottom portion 104a formed so as to extend below the bottom portion 103a of the holding chamber 103. As illustrated in this embodiment, preferably, the holding chamber 103 is formed at the bottom portion with anapproximately flat bottom 103a and the melting chamber 104 is formed with a downwardly concave round bottom 104a extending from the approximately flat bottom 103a. The heating means constituted with an electric heater 108 disposed at the holding chamber103 side and a gas burner 109 disposed at the melting chamber 104 side. As the electric heater 108, a flat heater well conformable to the approximately flat bottom 3a can be employed, and the gas burner 109 is mounted so as to face an opening of afurnace wall 101a. Thereby, temperature of molten magnesium M in the holding chamber 103 is controlled by the electric heater 108 without influence of temperature of molten magnesium in the melting chamber 104, and magnesium ingot charged to the meltingchamber 104 is melted by heating of the gas burner 109.
The molten metal charging apparatus 102 is constituted with a transfer pipe 106 with an electromagnetic pump 107 provided so as to communicate with the holding chamber 103 and a funnel 112 communicating with a delivery end of the transfer pipe106 and provided so as to be opposed to a molten metal supply port of an injection sleeve 150. The transfer pipe 106 can be heated by a heater 120 provided around the pipe 106.
A melt level B of molten magnesium in the transfer pipe 106 can be maintained close to the funnel 112 by performing a constant melt level control on the melting and holding furnace 101 during die casting work. Supply of molten magnesium to theinjection sleeve 150 is effected such that molten magnesium is delivered from the transfer pipe 106 to the funnel 112 by the electromagnetic pump 107 provided on transfer pipe 106 and a whole amount of molten magnesium delivered is poured into theinjection sleeve 150 via the funnel 112. At this time, as the molten metal to be handled is molten magnesium alloy, a space from the melt level B to a delivery side is put in a filled state with antideflagrant gas. Incidentally, an opening/closingshutter is provided at a lower part of the funnel 112 such that the lower part is put in a closed state at a time of non-supply of molten magnesium.
The tilting mechanism is constituted with an electrical lifter 113 in this embodiment. The electric lifter 113 is grounded at its distal end and it is rotatably mounted at its proximal end to the furnace wall 1a of a holding chamber 103 side ofthe melting and holding furnace 101. The melting and holding furnace 101 is maintained horizontally during die casting by the electrical lifter 113 and a pivoting member (not shown) pivoting the furnace 110a of the melting chamber 104 side and it istilted around the pivoting portion of the melting chamber 104 side serving as a tilting fulcrum by stretching operation of the electrical lifter 113 as occasion demands such as maintenance work.
In this embodiment, a tilting fulcrum C serving at this time is provided at an approximately central portion of the melting chamber 104. Accordingly, as illustrated in FIG. 8, the melting and holding furnace 101 is tilted together with themolten metal supplying apparatus 102, and the transfer pipe 106 and the funnel 112 which are far from the tilting fulcrum C are tilted and maintained in a state in which they are spaced from the injection sleeve 150. A tilted or inclination angle.theta. in this tilted and maintained position is set so as allow easy discharging of molten magnesium M from the transfer pipe 106 of the molten metal supplying apparatus 102, the electromagnetic pump 107 and the like to the crucible 130.
In the melting and holding furnace with a titling mechanism thus structured, dross/sludge occurring in the melting chamber 104 during melting of magnesium ingot and/or molten magnesium M with a high specific gravity which has just beencold-charged to be melted are deposited or stayed at the round bottom 104a owing to differences in shape and in height between the bottom portions of the holding chamber 103 and the melting chamber 104 so that they can prevented from moving to theholding chamber 103. Thereby, trouble is also prevented from occurring at the inside of the transfer pipe 106 and die cast products of a good quality can be obtained in a stable manner.
Also, respective temperature controls in the holding chamber 103 and the melting chamber 104 can respectively be performed by the electric heater 108 and the gas burner 109 independently from the temperatures in the adjacent chambers 103 and 104,and, in addition thereto, the temperature of molten magnesium in the holding chamber 103 can be controlled or adjusted with a high accuracy by a rapidly controllable electric heater 108 while molten magnesium M with a high specific gravity which has justbeen melted down is prevented from flowing in the holding chamber 103. Also, magnesium ingot charged to the melting chamber 104 can be rapidly melted by excellent heat transfer of the gas burner 109 to the round bottom 104a. Particularly, variation influidic characteristic of temperature of molten magnesium M in the transfer pipe 106 can be suppressed by maintaining the temperature of molten magnesium in the holding chamber 103 so that a supply amount of molten magnesium is made stable. As a result,die cast products can be obtained in a stable manner.
Also, when the melting and holding furnace 101 together with the molten metal supplying apparatus 102 is tilted and maintained in the tilted position by the electrical lifter 113, molten magnesium M in the molten metal supplying apparatus 102 canbe delivered in the crucible 130 without staying, so that maintenance work can easily be effected on, for example, the transfer pipe 106, the heater 120 thereabout, or the like.
Furthermore, as the bottom portion of the melting chamber 104 is formed in the round bottom 104a, melting work in which supply work of molten magnesium is not effected can be effected while the melting and holding furnace 101 is maintained in itstilted position (refer to FIG. 8), so that dross/sludge occurring during melting work and molten magnesium M with a high specific gravity which has just melted down can approximately completely be prevented from moving to the holding chamber 103. As aresult, troubles occurring in the inside of the transfer pipe 106 are suppressed so that maintenance work can be facilitated and die cast products of a good quality can be obtained in a more stable manner.
FIGS. 9 and 10 illustrate an ingot charging apparatus 201 according to the fifth embodiment. The ingot charging apparatus 201 is for charging a preheated magnesium ingot MA from a preheating apparatus 202 to a melting and holding furnace 203,and it is constituted with conveying means 205 for discharge each preheated magnesium ingot MA from the preheating apparatus 202 by holding it by an ingot chuck 204 and for conveying the preheated magnesium ingot MA to the melting and holding furnace 203to discharge and charge the same thereto, and a hood 208 mounted to the conveying means 205, which, at a time of discharge the preheated magnesium ingot MA and at a time of charging the same, communicates with an ingot discharge port 202a of thepreheating apparatus 202 and an ingot charge port 203a of the melting and holding furnace 203a to form closed spaces 207 and 206 for allowing discharge operation of the preheated magnesium ingot MA and charge operation thereof and which covers thepreheated magnesium ingot MA held by the ingot chuck 204 during conveyance of the preheated magnesium ingot MA.
The preheating apparatus 202 is constituted with a moving stand 222 having a frame on which magnesium ingots MA can be put in their standing manner such that their longitudinal axes are vertical, a preheater (not shown), an ingot discharge port202a, and a discharge port shutter 220 for opening/closing the ingot discharge port 202a. The moving stand 222 is disposed to be movable in a tact feeding manner and the interior of the preheating apparatus 202 is preheated to a preheating temperature. The ingots MA on the moving stand 222 are moved while being heated and their are raised. Each ingots MA on the moving stand 222 whose preheating has been completed is put in a standby state below the closed discharge shutter 220. The preheatedcondition of the ingot MA is monitored by a thermocouple temperature sensor (not shown). The discharge shutter 220 is provided to be movable in a reciprocating manner by a shutter driving cylinder 221, and it is put in a closed state when discharge ofthe ingot MA is not effected. The ingot discharge port 202a is formed such that a tubular or cylindrical body 202c provided at its upper part with a flange-shaped hood receiver 202b is provided at an upper part of the preheating apparatus 202 so as tocommunicate with an interior thereof. The ingot discharge port 202a is closed by placing the discharge shutter 220 on the hood receiver 202b (refer to FIG. 9).
The melting and holding furnace 203 includes therein a holding chamber 210 and a melting chamber 211 which are partitioned by a partition portion 213 such that molten magnesium M can flow in these chambers 210 and 211 mutually. Upper openings ofthe holding chamber 210 and the melting chamber 211 are closed by a furnace lid 217. The furnace lid 217 has gas injection ports 233 and 234 for respectively injecting antideflagrant gas G into the holding chamber 210 and the melting chamber 211 and aningot charge portion 203a corresponding to the melting chamber 211. The ingot charge port 203a is formed such that a tubular or cylindrical body 203c provided at its upper part with a flange-shaped hood receiver 203a is provided at the furnace lid 217so as to communicate with the interior of the melting and holding furnace 203. The ingot charge port 203a is closed by a charge port shutter 218 for flame prevention and heat insulation when charging of the ingot MA is not conducted. The charge portshutter 218 is disposed so as to be movable in a reciprocating manner by a shutter driving cylinder 219. The ingot charge port 203a is closed by the charge port shutter 218 thereon (refer to FIG. 10).
Also, a melt level detecting portion 230 is provided in the holding chamber 210 of the melting and holding furnace 203. The melt level detecting portion 230 is constituted with a float 231 floating on molten magnesium M, an indication portion231a implanted on the float 231 projecting above the furnace lid 217, and two sensor portions 232 provided at a projecting portion of the indication portion 231a so as to be opposed to each other along a vertical direction. The melt level detectingportion 230 detects the position of the indication portion 231a moving vertically according to an amount of molten magnesium M in the holding chamber 210 to detect the melt level B of molten magnesium M in the holding chamber 210 (and the melt level A ofmolten magnesium M in the molten metal transfer pipe 215a).
Furthermore, a molten metal supplying apparatus 214 for supplying molten magnesium M in the holding chamber 210 to an injection sleeve 216 of a die casting machine is provided at the holding chamber 210 of the melting and holding furnace 203 soas to communicate therewith. The molten metal supplying apparatus 214 transfers molten magnesium M in the furnace 203 via the molten metal transfer pipe 215a by an electromagnetic pump 215 to supply the same in the injection sleeve 216 from a deliveryend of the molten metal transfer pipe 215a. A delivery amount of molten magnesium M supplied by the electromagnetic pump 215 is set according to the size of a die casing product and/or the heights of molten magnesium melt levels (melt levels B and C)such that a constant amount of molten magnesium is supplied to the injection sleeve 216 (refer to FIG. 9).
In this embodiment, the conveying means 205 is constituted with an air-type rodless cylinder 224 mounted horizontally to a strut 225, an electromotive ball screw 240 moved horizontally along the rodless cylinder 224, and the ingot chuck 204 fixedto the electromotive ball screw 240. The electromotive ball screw 240 is configured with a nut member 226 mounted rotatably on a cylinder weight receiving portion 227 of the rodless cylinder 224 to be rotated by drive of a motor 228, and a ball screwportion 223 provided so as to be engaged with the nut member 226 in a threading manner and to pass through the nut member 226 and a guide portion 227a (refer to FIG. 12) of the cylinder weight receiving portion 227. The ball screw portion 223 is movedvertically by rotation of the nut member 226. The ingot chuck 204 is mounted to a lower end portion of the ball screw portion 223 and it is controlled so as to hold or grasp the ingot MA and release the same grasped according to instruction signals froma control portion (not shown).
The moved position of the rodless cylinder 224 is indicated with the position of the cylinder weight receiving portion 227. Accordingly, the cylinder weight receiving portion 227 together with the electromotive ball screw 240 is structured so asto be moved horizontally on the cylinder 224 according to cylinder instructions.
In this embodiment, a position `a` (refer to FIG. 9) where the ingot MA is held or grasped and a position b (refer to FIG. 9) where the ingot MA is released are determined on the cylinder 224, and the ball screw portion 223 is moved horizontallybetween the two positions `a` and b. The releasing position b corresponds to the ingot charge port 203a of the melting and holding furnace 203 and the grasping position b corresponds to the ingot discharge port 202a of the preheating apparatus 202.
As illustrated in FIG. 11, the hood 208 has such an inside diameter that it can accommodates the ingot chuck 204, and it is constituted with a tubular body 208c having an outer portion formed in a bellows shape stretchable/shrinkable in an axialdirection, a supporting plate 208b mounted to a proximal end portion of the ingot chuck 204 and fixed with an upper end portion of the tubular body 208c for supporting the tubular body 208c in a suspended position, and a ring member 208d forming anopening 208a of the hood 208, which is fixed at a lower end portion of the tubular body 208c.
Preferably, the hood 208 has a gas injection port 209 for antideflagrant gas. In this embodiment, the gas injection port 209 is provided in the supporting plate 208b.
Specifically, as illustrated in FIG. 11, the hood 208 is stretched with the own weight of the ring member 208d in a free position so as to cover the magnesium ingot MA held by the ingot chuck 204. When the magnesium ingot MA is taken out, thering member 208d abuts on the hood receiving portion 202b of the ingot discharge port 202a, in which the discharge port shutter 220 has been opened, to cause the opening 208a to communicate with the interior of the preheating apparatus 202, so that theclosed space 207 for allowing discharge operation of the ingot chuck 202 is formed in the hood 208 (refer to FIG. 10). When the magnesium ingot MA is charged, the ring member 208d abuts on the hood receiving portion 203b of the ingot charge port 203a,in which the charge port shutter 218 has been opened, to cause the opening 208a to communicate with the interior of the melting chamber 211, so that the closed space 206 for allowing charge operation of the ingot chuck 204 is formed in the hood 208(refer to FIG. 9).
That is, a preheated magnesium ingot MA is held by the ingot chuck 204 in a standing position in which its longitudinal axis is vertical, and it is taken out from the preheating apparatus 202 and conveyed by the conveying means 205. In a statein which antideflagrant gas G injected from the gas injection port 209 is filled in the closed space 206 formed by the hood 208 communicating with the ingot charge port 203a of the melting and holding furnace 203, most portion of the magnesium ingot MAis immersed in molten magnesium M in the melting and holding furnace 203 according to a low speed vertical downward movement of the ingot chuck 204, and then it is released and charged in the melting chamber 211.
In an ingot discharge step for discharge a magnesium ingot MA from the preheating apparatus 202, the ingot charging apparatus 201 put the ingot chuck 204 in a standby sate just above and near the upper part of the discharge port shutter 220. Atthis time, the ring member 208d positioned at a lower end of the hood 208 comes in contact with an upper face of the discharge port shutter 220. In the preheating apparatus 202, magnesium ingots MA which have been set on the moving stand 222 are put ina standby state.
In this state, the discharge port shutter 220 is opened according to a charging instruction or command from the melting and holding furnace 203. The charging instruction issued at this time may be a detection signal for detecting melt level B ofmolten magnesium in the melting and holding furnace 203 or a starting signal generated by a push bottom or the like operated by an operator observing the melt level B.
As the discharge port shutter 220 is opened, the ring member 208d abuts on the hood receiving portion 202b, further the ingot chuck 204 continues to lower according to downward movement of the ball screw portion 223, and it holds or grasps acompletely preheated magnesium ingot MA positioned at a predetermined height (refer to FIG. 10). At this time, the hood 208 allows downward movement of the ball screw portion 223 as a length of the hood 208 is shrunk along an axial direction.
Thereafter, the ball screw portion 223 is moved upwardly up to a home position, so that one magnesium ingot MA is securely taken out from the preheating apparatus 202. Immediately after discharge, the ingot discharge port 202a is closed by thedischarge port shutter 220.
In this ingot discharge step, as the closed space 207 is formed outside the ingot discharge port 202a by the hood 208, heat dissipation from the preheating apparatus 202 can be suppressed to the utmost.
Furthermore, after the ball screw portion 223 is moved upwardly to a predetermined horizontal movement position, the electromotive ball screw 240 is operated for a horizontal movement of the cylinder weight receiving portion 227 (ingot conveyingstep), the operation of the electromotive ball screw 240 is stopped when the cylinder weight receiving portion 227 reaches the position b for releasing the ingot MA on the cylinder 224, and downward movement of the ball screw portion 223 starts. At thistime, the gas injection port 209 starts to inject antideflagrant gas G in the hood 208.
In the ingot conveying step, as the preheated magnesium ingot Ma grasped by the ingot chuck 204 is conveyed in a state in which it is covered with the stretched hood 208 (refer to FIG. 11), heat dissipation is suppressed so that lowering of thetemperature of the ingot MA itself can be suppressed to the utmost.
In the course of downward movement of the ball screw portion 223, when the ring member 208d of the hood 208 comes in contact with the charge port shutter 218, the downward movement of the ball screw portion 223 is stopped once, and the chargeport shutter 218 is opened. Thereafter, as the ring member 208d abuts on the hood receiver 203b of the ingot charge port 203a and the closed space 206 filled with antideflagrant gas G is formed outside the ingot charge port 203a, the interior of themelting and holding furnace 203 is shielded from outside air.
In order to immerse the preheated magnesium ingot MA in the molten magnesium M from the ingot immersion start height, vertically downward movement of the ingot chuck 204 is effected at a low speed. For example, this downward movement isperformed at a much lower speed than the downward movement speed of the ball screw portion 223 before the contact of the ingot MA with the melt level B, or it is performed in an intermittent manner. This intermittent downward movement includes such anintermittent downward movement that, after the ingot MA is immersed by its 1/3 length, immersion thereof is stopped for 40 seconds, it is further immersed by its 1/3 length, immersion thereof is stopped for 30 seconds, and so on, or such an intermittentdownward movement that, just when the molten metal supplying apparatus 214 should start molten metal supply operation, downward movement of the ingot MA is stopped and downward movement thereof restarts after supply operation of molten magnesium has beencompleted. The latter intermittent downward movement is effected such that identical conditions can be obtained at respective molten magnesium supply times (casting times) and stable casting conditions can be obtained for the respective molten magnesiumsupply times (casting times). Such a low speed downward movement of the ingot chuck 204 can be made possible by suppressing oxidization of molten magnesium in the melting chamber 211 with antideflagrant gas G filled in the closed space 206.
When the height of the ingot chuck 204 moving downward reaches a predetermined height, most portion of the preheated magnesium ingot MA is immersed in molten magnesium M. At this time, the ingot chuck 204 releases the preheated magnesium ingot MAinto molten magnesium M in the melting chamber 211.
In this ingot charging step, as the preheated magnesium ingot MA is immersed, with its standing position in which its longitudinal axis is vertical, into the melting and holding furnace 203 (melting chamber 211) from the ingot charge port 203a,the opening area of the ingot charge port 203a can be set small, and correspondingly heat dissipation from inside of the melting and holding furnace 203 can be suppressed.
Also, as immersion of the preheated magnesium ingot MA to molten magnesium M is performed at a state in which antideflagrant gas G is filled in the closed space 206 and by vertically downward movement of the ingot chuck 204 at a low speed, theimmersion can be carried out in a state in which oxidization of molten magnesium, variation in molten magnesium temperature, and/or disturbance of molten magnesium melt level and antideflagrant gas atmosphere is suppressed.
After this ingot charging step, when the electromotive ball screw 240 is put in an upward movement operation so that the ball screw portion 223 is moved upwardly to reach a predetermined height, the ingot charge port 203a is closed by the chargeport shutter 218 and injection of antideflagrant gas G from the gas injection port 209 is stopped. Furthermore, when the ball screw portion 223 continues to move upwardly and reaches the height where the ingot chuck 204 can be moved horizontally, theupward movement thereof is stopped. Then, the ingot chuck 204 is put in a horizontal movement operation on the rodless cylinder 224, and the horizontal movement of the ingot chuck 204 is stopped at the position `a` for grasping an ingot on the cylinder224, where downward movement of the ball screw portion 223 starts as an operation for discharge another magnesium ingot MA from the preheating apparatus 202. The downward movement is further effected and stopped once at a predetermined height where thering member 208 comes in contact with the discharge port shutter 220. At this position, the ingot chuck 204 is put in a standby state.
At this time, in the preheating apparatus 202, another ingot MA set on the moving stand 222 is made to stand by below the discharge port shutter 220. In this state, the discharge port shutter 220 is opened according to a charging instructionfrom the melting and holding furnace 203. The ring member 208b abuts on the hood receiver 202b of the ingot discharge port 202a through the opening, and the ingot chuck 204 continues to moved downward, so that the completely preheated magnesium ingot MAis grasped or held by the ingot chuck 204 at a predetermined height.
Thereafter, the operation of the ingot charging apparatus 201 is repeated. The magnesium ingot MA charged is melted near the ingot charge port 203a of the melting chamber 211 and molten magnesium M obtained by melting ingots moves to the holdingchamber 210 positioned at an electromagnetic pump 215 inlet side through the partition plate 213.
According to the ingot charging method employing the ingot charging apparatus 201, thus, magnesium ingots MA can be charged to the melting and holding furnace 203 on the basis of instructions from the melting and holding furnace 203 withoutdisturbing molten magnesium melt level and antideflagrant gas layer within the melting and holding furnace 203, and oxidization of molten magnesium M can be reduced and dross/sludge can be suppressed from occurring, which results in improvement inquality of die cast products obtained.
Also, as the ingot MA is charged with its standing position, the opening area of the ingot charge port 203a can be reduced. In the ingot charging step, as the closed space 206 is formed outside the ingot charge port 203a, heat dissipation fromthe interior of the melting and holding furnace 203 can be suppressed to the utmost so that molten magnesium temperature in the furnace 203 is made stable. As a result, when casting operation is performed in a die casting machine, fluidity of moltenmagnesium MA is prevented from deteriorating or varying, and die cast products of a good quality can be obtained in a stable manner.
Furthermore, automatic charging of preheated magnesium ingots MA is made possible, and thereby elimination or reduction of labor is not only allowed but also stabilization of the quality of die cast products obtained can be obtained in spite ofrepetitive charging of an ingot MA.
Besides, as the downward movement of the ingot chuck 204 in the ingot charging step can be effected at a low speed, variation of molten magnesium temperature at a charge time of an ingot MA and/or variation of melt level can be reduced to a greatextent, thereby reducing variation of dynamic pressure in the molten metal transfer pipe 215a. In the molten magnesium supply system employing the electromagnetic pump 215 in this embodiment, metering accuracy for the delivery amount of molten magnesiumis improved and molten magnesium of a constant and appropriate amount can be supplied.
This embodiment employs the method in which the ingot chuck 204 is moved horizontally between the position `a` for grasping an ingot MA and the position `b` for releasing the same on the rodless air cylinder 224, but the present invention is notlimited to this method. The present invention may employ a method in which the vertical movement of the ingot chuck 204 is effected by an electromotive ball screw type drive similar to that of the embodiment, but movement of the ingot chuck 204 betweenthe two positions `a` and `b` is performed by a mechanism in which the electromotive ball screw 240 is mounted to a side plate portion rotatably provided on the strut 225 and the electromotive ball screw 240 is pivoted about the strut 225, thereby movingthe electromotive ball screw 240. In this case, as charge operation of a preheated magnesium ingot MA can be performed by moving the ingot chuck 204 between the two positions `a` and `b` through the pivoting operation of the electromotive ball screw240, simplification of the structure of an ingot charging apparatus can be facilitated.
In this embodiment, the melting and holding furnace 203 is constituted with the holding chamber 210 and the melting chamber 211 partitioned by the partition portion 213, but this invention is not limited to this constitution. Of course, thepresent invention is applicable to a melting furnace in a case of two-pot type in which a melting chamber and a holding chamber are provided independently from each other.
While preferred embodiments of the present invention have been described using specific terms, such description is for illustrative purposes, and it is to be understood that changes and variations may be made without departing from the scope ofthe following claims.
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