Improvements in or relating to Apparatus for Casting Metals.
Year: 1899

page_text: COMPLETE SPECIFICATION.
Improvements in or relating to Apparatus for Casting Metals.
I, ARTHUR LUCIAN WALKER, of Perth Amboy, New Jersey, United States of
America, Mining Engineer and Metallurgist, do hereby declare the nature of
this invention and in what manner the same is to be performed, to be particu-
larly described and ascertained in and by the following statement:—
My invention has reference to improvements in apparatus for casting metals,
especially those which are ladled or tapped out of the furnace, such as copper,
and poured into molds; and it relates more particularly to casting apparatus
of that type wherein the molds are mounted upon a rotary table or carrier and are
thereby successively brought into position to receive the molten metal from the
ladle and thence conveyed to the bosh or a dry pit, where the castings are dumped.
The object of the invention is to improve generally the construction of casting
apparatus of this character and to provide improved ladling and mold-carrying
mechanism whereby the successive operations of casting on a large scale may be
accomplished with great rapidity, safety, at small cost, and with a minimum
amount of labor and without waste.
With this and other objects in view the invention consists in the novel con-
structions and combinations of parts hereinafter more fully described, and par-
ticularly pointed out in the appended claims.
In the accompanying drawings;-
Figure 1 is a side elevation, partly in section, and partly broken away to
illustrate more completely internal and hidden parts of the mechanism.
Figure 2 is a top plan view of the apparatus.
Figure 3 is a sectional view, taken at right angles to Figure 1, to illustrate
more completely internal and hidden parts of the mechanism.
Figure 4 is a detail elevation of the deflector supporting mechanism on an
enlarged scale, and
Figure 5 is a similar view, looking at the left-hand end of the mechanism
illustrated in Figure 4.
Figures 6 and 7 are detail views showing forms of molds employed.
Figures 8, 9 and 10 are details of one form of ladle.
Figures 11 and 12 are details of another form of ladle.
Like letters of reference in the several figures indicate the same parts.
Referring to Figures 1, 2 and 3, particularly Figure 3, it will be seen that upon
a suitable foundation 1, there is arranged a central upright or post 2 surrounded
by a concentric track or way 3, the diameter of which should be made sufficient
to afford the necessary support to the carrier and which is preferably of a diameter
equal to that of the carrier proper. This carrier, which as shown, is preferably

page_text: made in the form of a wheel, having its central hub 4 journaled on the upright 2,
and joined by a series of arms 5, with a relatively wide peripheral flange 6. The
flange 6 extends some distance above the level of the arms 5, in the form of
apparatus shown and its lower edge is widened out to afford a bearing 7, which
through the medium of anti-friction rollers 8, cooperates with the track or way 3.
The rollers S may be suitably supported and spaced by spacing rings 9, arranged
to connect their journals, as will be readily understood.
The peripheral flange 6 of the carrier is adapted to support a series of adjust-
able bracket arms 10 in the outer edge of which the molds for the metal are
journaled in suitable bearings formed in the arms and upon journals or trunnions
either formed directly upon the molds themselves or connected with the molds in
any suitable manner. The trunnions are located forward of and below the center
of gravity of the mold, and the mold is normally held supported by its flange
resting upon the cross-bar 74. The brackets being adjustable permit of the use
of molds of various sizes and shapes. Different molds are of unequal length, and
if no bushings are used the bearings in the brackets may be formed to accommodate
the bearings at any angle. Thus provision is made to enable any size or shape
of mold to be used in this apparatus.
The molds mounted on the carrier are adapted to receive the imolten metal
from any suitable source, as, for instance, from the furnace 11, through mechanism
to be presently described, and to be conveyed thence to the dumping point, as
will also be presently described, and in order to give the carrier the movement
necessary for carrying out this operation, I preferably mount on the central
upright or pivot, of the carrier, a fixed platform 12, Figure 3, upon which an
attendant may stand, and upon this platform, I also mount the rotating mechanism
for the carrier. This mechanism is preferably operated hydraulically, although
other power, such as an electric motor, may be employed, but as shown, it consists
of a hydraulic cylinder 13, the piston rod 14 of which is connected with a pulley 15
through the medium of a flexible connection 16 and this pulley 15 is journaled
upon a vertical shaft 17, the whole being in turn journaled on the
stationary platform 12. A ratchet and pawl connection 18 is interposed between
the pulley 15 and shaft 17, whereby when the piston is forced in one direction,
the shaft 17 will be rotated, but when said piston is moving in the opposite
direction and the pulley 15 operating in the correspondingly opposite direction,
no movement will be imparted to the said shaft. To secure this reverse
movement of the pulley 15, a flexible connection 19, passing around a relatively
small drum 20 on said pulley, extends over an idler pulley 21, and has connected
to it a weight 22 which tend's constantly to draw the flexible connection in a
direction to move the pulley 15 reversely. As the piston is moved to advance
or rotate the shaft 17 forwardly, the weight 22 will be raised and when the power
or pressure in the cylinder is released, the weight will move the parts reversely.
Upon the lower end of the shaft 17 there is mounted a wheel 23 which meshes
with a relatively large gear wheel 24, mounted on the arms 5 of the carrier. The
pressure to the operating cylinder 13 is controlled by a hand lever 25, Figure 1,
arranged in position to be conveniently reached by the attendant standing on the
platform and from which point it will be noted that he is in position to survey
all of the molds held by the carrier and may therefore control the movement of
the carrier with the utmost facility. In addition the attendant on this central
platform may control the whole apparatus, when it is so desired, inasmuch as all
the controlling levers and handles may be placed within his reach, thus materially
economizing labor.
Between the molds and the melting furnace or other source from which the
molten metal is supplied to the molds, there is arranged a ladle 26, the forward
end of which is supported upon rocking arms or trunnions 27, so as to advance
or move backwardly the pouring end of the ladle without materially changing
its level, the said pivotal point between the ladle and trunnions being also at

page_text: approximately the level and very near the front end of the pouring spout, or
discharge opening of the ladle, as a further protection against any change of level
during the pouring operation and consequently ensures a uniform dropping of the
metal from a very short height into the mold. The rear end of the ladle is
suspended from a connection 28, the upper end of which passes over a pulley 29
firmly attached to the framing and extends thence to a hydraulic or power
cylinder 30, the pressure to which is controlled through a hand lever 31, located
at any convenient point within reach of the attendant. The rocking trunnions
of the ladle are also preferably controlled by a hand lever 32 also preferably
located within reach of the same attendant who controls the hand lever 31, and
all the handles may, if desired, be brought within reach of the attendant on the
central platform, thus the attendant watching the pouring operation, may, single-
handed, watch and control accurately the entire pouring operation. In order to
ensure a more complete operation or result, or to further insure the delivery of
the metal to the mold and obviate all liability of clinging, splashing, or "cold-
setting, more particularly in some forms of special work, there may be inter-
posed between the ladle and the molds, during the pouring operation, a deflector,
the particular formation of which is varied to suit the material and form of cast-
ing being made. In the present instance this deflector is supported from the
central platform of the carrier and is directly under the control of the attendant'
(located on the platform) through the medium of a handle, which extends up
over the peripheral rim of the carrier, although it may be supported from over-
head, or elsewhere, if desired, but it will be understood that this deflector is not
essential but only optional in the use of the apparatus.
Various mechanisms may be arranged upon the central stationary platform for
supporting the deflector and in Figures 4 and 5 I have shown one form of such
mechanism, consisting of a substantially horizontal shaft 33, supported in bear-
ings 34 on the platform and adapted at one end to be adjustably connected with
the deflector arm 35, as by a sleeve and set screw connection 36, and at the other
end to support an operating or controlling handle 37 with a suitable counter-
weight 38 adjustable on said handle. The shaft 33 is adapted to be
moved in the bearings 34 longitudinally or to be rotated to swing
the deflector to one side or the other, as occasion requires, the counter-
weight 38 balancing the weight of the deflector and materially reducing the
labor of the attendant in manipulating the same. For limiting the longitudinal
movement of the shaft, adjustable collars 39 may be mounted thereon between
the bearings 34, thus the extreme range of movement of the deflector may be
limited or adjusted to conform to the formation or position of the molds, being
used at any particular time and the variation in the weight of the deflector used
may be compensated for by the adjustment of the counter weight 38 on the con-
trolling handle 37.
Should it be desired, a simple crane or over-hanging arm may be employed and
the deflector supported therefrom by a hanging connection.
Small castings or castings of small articles may be dumped out of their molds
when they have been carried a short distance only into a water bosh or dry pit 40,
while larger castings may be carried half way around or if desired, further, and
dropped into a bosh or pit containing water, if so desired, and conveyed away
automatically. The dumping operation may be performed automatically and I
have shown in the drawings, one arrangement for accomplishing this end. Upon
those molds which it is desired to dump automatically, a dumping handle or pro-
jection 41 is provided in such position that as the molds are advanced by the
carrier, the handle 41 will be brought into contact with an incline 42, supported
by a frame 43 and by said incline raised until the mold is inverted, when the
handle will slide down a second incline 44 until the said handle comes in contact
with and rests upon the top 45 of the box, and in this position, the casting will
drop out, the position of the mold being as shown in Figure 1, with its upper
end preferably below the level of the top of the bosh so as to lie in the water

page_text: contained in said bosh and kept approximately at the level of the top of the bosh.
The effect of the water is to cool the mold to fit it for the subsequent reception
of molten metal and in order to heighten this effect a spray 46 is preferably
arranged to play on the bottom of the inverted mold, as also indicated in Figure 1.
Before the mold leaves the bosh or reaches a position where its end might strike
the side wall of the bosh, the inverting arm 41 comes in contact with another
incline 47 up which it rides as the carrier continues its movement and by which
the mold is turned back to its original position, ready for the reception of the
molten metal when the mold reaches the receiving position again. Sufficient
heat will usually be retained by the mold to ensure its being completely dried
after leaving the bosh and before it reaches the receiving position in front of the
pouring ladle,
When castings are dumped into the water bosh, they slide down an inclined
floor 48 and are elevated from the bottom of the bosh by a slow moving elevator 49,
which will carry them up into position to be handled by the attendants or into
position to be conveyed away to any suitable source, for further treatment or sale,
as desired.
With an apparatus such as herein described, it will be observed that practically
the entire handling of the metal from the time it flows from the furnace or is
deposited in the pouring ladle until the completed castings are delivered is per-
formed by mechanical power, but under the direct control of the attendant, whose
labor, however, is very light, and as a result, not only is the operation of casting
facilitated and the speed with which castings may be made greatly enhanced,
but the castings receiving a uniform treatment will be more homogeneous and
uniform throughout the whole batch than it is possible where the metal is con-
veyed about and deposited in a series of molds which are subsequently dumped
by hand.
It will be noted that the molds are pivoted on axes which are eccentric to or
forward of and below the center of gravity of the molds, thus the molds will
normally retain their initial position with the flanges or stop projections on their
inner sides engaging the supporting brackets or cross bars 74, and, in the present
instance, a greater proportion of the molds which are intended to be subjected to
the action of the water in the water bosh lies above their axes. The result of
this arrangement is that when inverted the lower portion of the inverted mold
(formerly the top of the mold) occupies a plane which is lower than the normal
plane of the bottom of the mold and hence when inverted, the top of the mold
may extend down into the water within the water bosh, as before explained, the
wails of the bosh for this purpose being higher than the plane of the lower portion
of the inverted mold, but lower than the normal level of the bottom of the mold
when in initial position.
In some instances it is desirable to cast a number of small articles such as
wire bars or the like by simultaneous pouring and in such cases a ladle having
multiple pouring openings, as in Figures 8, 9 and 10, wherein 50 indicates the
body of the ladle and 51 the pouring openings, may be employed.
The multiple mouth ladle is also especially advantageous where the casting is
a thin plate of large dimensions, inasmuch as with it the metal is quickly and
evenly distributed over the whole surface of the mold and no cold setting, bank-
ing or splashing of the metal takes place. In fact the multiple mouth ladle may
be used wherever a more even distribution of metal is desired in any form of
mold and in many cases may be employed to advantage dispensing with the use
of the deflector.
This last mentioned form of casting i.e., thin plates of large dimensions in a
machine has been difficult not alone by reason of the difficulties above indicated,
but also because of the liability of the metal molds warping or bending out of
shape, and in order to overcome this difficulty I have now provided a mold
(Figure 7) in which a cast iron supporting frame 52 having end trunnions 53 is

page_text: employed, in connection with a copper insert 54, provided with the mold cavity 55.
The walls of the frame are undercut and a key 50 is used to secure the two parts
rigidly together. This mold is adapted for general use in casting plates of any
metal.
I desire it understood that I do not limit myself to the specific details of con-
struction of ladle herein shown and described, but reserve to myself the right to
make such changes in the form and arrangement of the same and of the various
parts of the apparatus as fairly fall within the spirit and scope of my invention.
Where it is desired to distribute the metal side ways the mouths or pouring
openings in the ladle may be on the side, as shown for instance
in Figures 11 and 12, where
indicates the body of the ladle
and 57 the pouring openings and the latter it will be understood
may be two or more in number, especially when a mold having a number
of cavities is employed as in Figure 6, (although the deflector is preferably used
to secure the distribution of the metal in such molds).
نات
Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is to be performed, I declare that what
I claim as new and desire to secure by Letters Patent, is :-
-
1. In a casting apparatus, the combination with a mold carrier having mold
supporting brackets mounted thereon, and means for rotating it in a horizontal
plane of a fixed platform mounted centrally of said carrier and controlling
mechanism for governing the movement of the carrier located on said platform;
substantially as described.
2. In a casting apparatus, the combination of the horizontally rotating mold
carrier, a central fixed shaft or support about which said carrier rotates and a
fixed platform supported by said shaft, and forming a stable base for the operator;
substantially as described."
3. In a casting apparatus, the combination of the mold carrier and means for
rotating it in a horizontal plane, a central fixed shaft or support about which
said carrier rotates and a fixed platform supported by said shaft with carrier con-
trolling mechanism mounted on said platform; substantially as described.
4. In a casting apparatus, the combination with the horizontally rotatable
carrier having the mold brackets mounted thereon, of a central shaft about which
said carrier rotates, projecting up through the carrier, a horizontal platform
mounted on the upper end of said shaft and fixed with relation to the carrier, a
driving mechanism mounted on said platform, gearing interposed between said
driving mechanism and carrier and a controlling handle for said driving
mechanism; substantially as described.
5. In a casting apparatus the combination with the horizontally rotatable
carrier, having mold supporting brackets projecting therefrom and a central shaft
about which said carrier rotates projecting up through the carrier, of a platform
supported on said shaft above the carrier, a hydraulic cylinder mounted on the
platform, a piston working in said cylinder, a shaft rotated by the movement of
the piston and gearing interposed between said shaft and carrier as set forth.
6. In a casting apparatus, the combination with a horizontally rotatable carrier,
of a driving mechanism for rotating said carrier embodying a hydraulic cylinder
and piston, a shaft, connectious between said piston and shaft whereby the latter
is rotated with a ratchet interposed in said connections for preventing reverse
movement of the shaft and gearing interposed between the shaft and carrier:
substantially as described.
7. In a casting machine, the combination with a horizontally rotatable carrier,
having mold supporting brackets projecting therefrom, of a driving mechanism
for rotating said carrier embodying a hydraulic reciprocating motor, a drum and
connections between the motor and drum, whereby the latter is rotated in one
direction by the motor, a weight connected with the drum for rotating it in the

page_text: opposite direction, a shaft geared with the carrier and a pawl and ratchet con-
nection interposed between the drum and shaft; substantially as described.
8. In a casting machine, the combination with a horizontally rotatable carrier,
and a series of pivoted dumping molds mounted on and entirely supported thereby
with controlling arms for said molds, of inclines with which said arms cooperate
as the carrier rotates to invert said molds and discharge the castings; substantially
as described.
9. In a casting apparatus, the combination with a horizontally rotatable carrier,
having a series of mold supporting brackets projecting therefrom, dumping molds
pivoted on horizontal axes tangential to the carrier in said supporting brackets
and entirely supported thereby and controlling arms for said molds, of an incline
located in the path of travel of said controlling arms, whereby the molds are
inverted to discharge the castings, and reverse inclines also located in the path
of travel of said controlling arms for returning the molds to their initial position;
substantially as described.
10. In a casting apparatus, the combination with the horizontally rotatable
carrier, the mold supporting brackets carried thereby, the molds journaled in said
arms on horizontal axes and controlling arms for said mold, of an incline lying
in the path of travel of said controlling arm for inverting the mold, a second
incline with which said arms cooperate, and down which they travel as the molds
become inverted and a reverse incline lying in the path of travel of said arms
when the molds are in their inverted position for returning the molds to their
initial position; substantially as described.
11. In a casting apparatus, the combination with a horizontally rotatable
carrier and a series of molds supported thereby, of a central stationary platform
arranged within said carrier, a pouring ladle for supplying molten metal and a
universally movable deflector interposed between said ladle and molds, with a sup-
port for said deflector carried by the central fixed platform; substantially as
described.
12. In a casting apparatus, the combination with the horizontally rotatable
carrier, a series of molds supported thereby, a pouring ladle for supplying molten
metal to said mold and a fixed support or platform, of a substantially horizontal
shaft mounted in bearings on said platform to rotate and move longitudinally
a deflector carried by said shaft and adapted to be interposed between the ladle
and mold, and a controlling handle and counter-weight also carried by said shaft
for manipulating the deflector; substantially as described.
13. In a casting apparatus, the combination with the horizontally rotatable
carrier, the series of molds supported thereby, a pouring ladle for supplying
molten metal to the mold and a fixed platform, of a substantially horizontal
deflector supporting shaft mounted in bearings on said platform so as to be
capable of a rotary and a longitudinal movement, a vertically adjustable deflector
arm carried by one end of said shaft with a deflector connected with said arm
and adapted to be interposed between the ladle and molds, and a controlling
handle and counter-weight carried by the opposite end of said horizontal shaft;
substantially as described.
14. A mold for use in casting apparatus consisting of a frame having a recess
therein and an independent insert containing the mold cavity keyed in the recess
in the frame; substantially as described.
15. A mold for use in casting apparatus consisting of an iron frame having a
recess therein and a copper insert keyed in said recess and having the mold cavity
in its upper surface, substantially as described.
16. In a casting apparatus, the combination with the carrier adapted to support
a series of molds, of a ladle for supplying molten metal to the molds on the
carrier having trunnions near its pouring end and a multiplicity of pouring
mouths, with power mechanism for tilting said ladle.
17. In a casting apparatus, the combination with the carrier adapted to support
a series of molds, of a ladle for supplying molten metal to the molds on the carrier

page_text: having trunnions near its pouring end and a multiplicity of pouring mouths, with
pivoted trunnion supports or bearings and a power mechanism for tilting the
ladle.
18. In a casting apparatus, the combination with the mold carrier and operating
mechanism, of a ladle having side pouring mouths for distributing the metal
transversely.
BOULT & WADE,
Agents for the Applicant.