Furnace tap hole flow control and tapper system and method of using the same
AssigneeGillespie & Powers, Inc.
InventorsJon Richard Gillespie, Robert Alan Nash, II, Gregory Kurt Schroeder
Life of this patent
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Abstract
A molten metal flow controller (10) for a metal melt furnace having a tap hole (T) to release the molten metal from the furnace, where the controller (10) is configured to controllably release the flow of molten metal through the tap hole (T) using an actuator (14) that controllably moves a plunger (110) into and out of the tap hole (T) in response the increase or decrease in the molten metal flow rate through the tap hole (t) as measured by a sensor (130).
Claims25
In combination with a metal melt furnace having a tap hole through which is released a flow of molten metal, a molten metal flow controller for controllably releasing the flow of molten metal comprising:
- a plunger controllably movable into and out of the tap hole;
- an actuator to which the plunger is operatively connected, the actuator being configured to controllably move the plunger relative to the tap hole;
- and
- a sensor configured to measure the flow rate of molten metal from the tap hole and generate one or more outputs reflecting such flow rate;
- wherein the actuator is configured to respond to the one or more outputs from the sensor so as to direct the plunger away from the tap hole when the flow of molten metal is less than a first predetermined flow rate and direct the plunger toward the tap hole when the flow rate is greater than a second predetermined flow rate.
A molten metal flow controller for controlling the flow of molten metal through a tap hole in the furnace comprising:
- a tapper having a plunger, the plunger configured to be removably insertable into the tap hole for regulating the flow of molten metal through the tap hole;
- a fixture removably attachable to a side of the furnace in proximity to the tap hole, the tapper being supported by the fixture;
- an actuator mounted on the fixture and to which the tapper is connected, the actuator configured to move the plunger relative to the tap hole;
- and
- a programmable controller configured to control the actuator to move the plunger relative to the tap hole as a function of the flow rate of molten metal through the tap hole.
An apparatus for tapping a metal melt furnace and controlling the flow of molten metal through a tap hole in the furnace comprising:
- a binary tapper having a first actuator and a first plunger, the first plunger configured to be removably insertable into the tap hole and to fully close the tap hole when fully inserted therein, the first actuator operatively connected to the first plunger and configured to alternately fully insert the first plunger into the tap hole to preclude the flow of molten metal through the tap hole or retract the first plunger from the tap hole to allow for the flow of molten metal through the tap hole;
- and
- a discrete tapper having a second actuator and a second plunger, the second plunger removably insertable into the tap hole, the second actuator operatively connected to the second plunger and configured to position the second plunger relative to the tap hole at one or more discrete locations in the flow of molten metal exiting the tap hole.
A method of controlling the flow of molten metal from a metal melt furnace having a tap hole, the method comprising the steps of:
- constructing a plunger that is configured to fit at least partially in the tap hole and to controllably move into and out of the tap hole;
- positioning the plunger in proximity to the tap hole;
- operatively connecting the plunger to an actuator configured to position the plunger relative to the tap hole;
- measuring the flow rate of molten metal from the tap hole;
- controlling the actuator to move the plunger toward the tap hole when the flow rate is greater than a predetermined flow rate so to decrease the flow of molten metal through the tap hole, and to move the plunger away from the tap hole when the flow of molten metal is less than a predetermined flow rate so to increase the flow of molten metal through the tap hole;
Dependencies are inferred from the claim text.