Molten metal pouring device and molten metal pouring method
AssigneesSintokogio, Ltd., Fujiwa Denki Co., Ltd.
InventorsTadashi NISHIDA, Toshiyuki HYODO, Koichi BANNO
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Abstract
A pouring apparatus comprises a ladle configured to include a body and a nozzle, and a controller configured to control a tilt angle of the ladle, wherein the body includes a side face portion, an inner surface of the side face portion is formed in a cylindrical shape or in a conical shape, the nozzle includes a nozzle tip for guiding molten metal to the outside and is integrated with the body on a side of the body, in order to guide the molten metal in the body to the nozzle tip and to pour out the molten metal through the nozzle tip, and the controller controls the tilt angle on the basis of a surface area of the molten metal when the ladle is tilted.
Claims20
1:
- A pouring apparatus for pouring by tilting a ladle such that a molten metal pouring position in which the molten metal is poured from a nozzle of the ladle is maintained at a predetermined position, comprising:
- the ladle configured to include a body and the nozzle, and
- a controller configured to control a tilt angle of the ladle,
- wherein the body includes a side face portion, an inner surface of the side face portion is formed in a cylindrical shape or in a conical shape,
- the nozzle includes a nozzle tip provided at one end thereof and is integrated with the body on a side of the body, in order to guide the molten metal in the body to the nozzle tip and to pour out the molten metal through the nozzle tip, and
- the controller controls the tilt angle of the ladle on the basis of a surface area of the molten metal when the ladle is tilted.
2:
- The pouring apparatus according to claim 1, wherein
- the nozzle is formed such that a surface area of the molten metal stored in the nozzle is in a shape of a trapezoid or a rectangle as viewed from a vertical direction when the ladle is not tilted and a surface area of the molten metal stored in the nozzle is in the shape of a trapezoid or a rectangle as viewed from the vertical direction when the ladle is tilted to pour out the molten metal through the nozzle tip.
3:
- The pouring apparatus according to claim 2, wherein
- the body has a surface area of the molten metal therein that is in the shape of an ellipse or an ellipse with missing part when the ladle is tilted to pour out the molten metal through the nozzle tip, the missing part being due to the molten metal decreasing such that the bottom of the tilted body is no longer covered.
4:
- The pouring apparatus according to claim 3, further comprising:
- a surface area information storage unit configured to store a surface area of the molten metal that is previously calculated in accordance with the tilt angle of the ladle.
5:
- The pouring apparatus according to claim 4, further comprising:
- a molten metal pouring pattern storage unit configured to store information on a molten metal pouring pattern corresponding to each mold to be conveyed,
- wherein the controller controls tilt operation of the ladle such that the molten metal is poured into the mold on the molten metal pouring pattern corresponding to a kind of product on the basis of the information on the molten metal pouring pattern corresponding to each mold, stored in the molten metal pouring pattern storage unit, and information stored in the surface area information storage unit.
6:
- The pouring apparatus according to claim 5, wherein
- the body includes a second inner side face portion aligning with a bottom portion of the nozzle in a section orthogonal to a tilt center.
7:
- The pouring apparatus according to claim 6, wherein
- the nozzle tip is provided with a curved surface with a predetermined curvature radius for forming a flow of the molten metal, and
- the ladle is tilted such that a curvature center of the curved surface serves as the tilt center.
8:
- The pouring apparatus according to claim 7, comprising:
- a horizontal movement mechanism configured to drive the ladle in a first direction that is a horizontal direction for approaching and separating from the mold;
- a lifting mechanism configured to drive the ladle in a second direction that is a vertical direction;
- and
- a rotation mechanism configured to rotate the ladle around a rotation axis that is parallel to a third direction orthogonal to the first direction and the second direction, and that passes through a center of gravity of the ladle,
- wherein the horizontal movement mechanism, the lifting mechanism, and the rotation mechanism drive the ladle to tilt the ladle such that the curvature center serves as the tilt center.
9:
- The pouring apparatus according to claim 8, comprising:
- a weight detector configured to detect weight of the molten metal in the ladle,
- wherein the controller controls tilt operation of the ladle by feedback control on the basis of information from the weight detector.
10:
- A pouring method for using a pouring apparatus for pouring by tilting a ladle such that a molten metal pouring position in which the molten metal is poured from a nozzle of the ladle is maintained at a predetermined position,
- the pouring apparatus comprising:
- the ladle configured to include a body and the nozzle, and
- a controller configured to control a tilt angle of the ladle,
- wherein the body includes a side face portion, an inner surface of the side face portion is formed in a cylindrical shape or in a conical shape,
- the nozzle includes a nozzle tip provided at one end thereof and is integrated with the body on a side of the body, in order to guide the molten metal in the body to the nozzle tip and to pour out the molten metal through the nozzle tip, and
- the molten metal pouring method allows the controller to control the tilt angle of the ladle on the basis of a surface area of the molten metal when the ladle is tilted so that the molten metal is poured out from the ladle.
11:
- The pouring method according to claim 10, wherein
- the ladle has an inner surface molded by using the mold for molding an inner surface of the body and the nozzle in a uniform shape.
12:
- A pouring apparatus for pouring by tilting a ladle such that a molten metal pouring position in which the molten metal is poured from a nozzle of the ladle is maintained at a predetermined position, comprising:
- the ladle configured to include a body and the nozzle, and
- a controller controlling a tilt angle of the ladle,
- wherein the controller controls the tilt angle of the ladle on the basis of a surface area of the molten metal when the ladle is tilted.
13:
- The pouring apparatus according to claim 1, further comprising:
- a surface area information storage unit storing a surface area of the molten metal that is previously calculated in accordance with the tilt angle of the ladle;
- a molten metal pouring pattern storage unit storing information on a molten metal pouring pattern corresponding to each mold to be conveyed;
- and
- a state storage unit storing various states,
- wherein the controller not only reads out a present tilt angle of the ladle stored in the state storage unit and a surface area inverse ratio corresponding to the present tilt angle from the surface area information storage unit, but also calculates present virtual tilt angular speed from the molten metal pouring pattern stored in the molten metal pouring pattern storage unit to calculate tilt angular speed required for the ladle on the basis of the matters above.
14:
- The pouring apparatus according to claim 13, wherein
- the molten metal pouring pattern stored in the molten metal pouring pattern storage unit corresponds to each mold, and is information showing change in virtual tilt angular speed with elapsed time, and
- the virtual tilt angular speed is angular speed in a case where a surface area of the mold is converted into a reference surface area on the basis of information on the surface area of the mold.
15:
- The pouring apparatus according to claim 13, comprising:
- a horizontal movement mechanism configured to drive the ladle in a first direction that is a horizontal direction for approaching and separating from a mold;
- a lifting mechanism configured to drive the ladle in a second direction that is a vertical direction;
- a rotation mechanism configured to rotate the ladle around a rotation axis that is parallel to a third direction orthogonal to the first direction and the second direction, and that passes through a center of gravity of the ladle;
- and
- a distribution calculation unit configured to calculate an amount of operation of the horizontal movement mechanism, the lifting mechanism, and the rotation mechanism to acquire required tilt angular speed calculated by the controller.
16:
- The pouring apparatus according to claim 15, wherein
- the molten metal pouring pattern includes information showing change in virtual tilt angular speed with elapsed time corresponding to at least an initial reaching time step, a stationary time step, a stable waiting time step, and an instruction region step, and
- the controller calculates virtual tilt angular speed according to each of the initial reaching time step, the stationary time step, the stable waiting time step, and the instruction region step.
17:
- The pouring apparatus according to claim 12, further comprising:
- a surface area information storage unit storing a surface area of the molten metal that is previously calculated in accordance with the tilt angle of the ladle;
- a molten metal pouring pattern storage unit storing information on a molten metal pouring pattern corresponding to each mold to be conveyed;
- and
- a state storage unit storing various states,
- wherein the controller not only reads out a present tilt angle of the ladle stored in the state storage unit and a surface area inverse ratio corresponding to the present tilt angle from the surface area information storage unit, but also calculates present virtual tilt angular speed from the molten metal pouring pattern stored in the molten metal pouring pattern storage unit to calculate tilt angular speed required for the ladle on the basis of the matters above.
18:
- The pouring apparatus according to claim 17, wherein
- the molten metal pouring pattern stored in the molten metal pouring pattern storage unit corresponds to each mold, and is information showing change in virtual tilt angular speed with elapsed time, and
- the virtual tilt angular speed is angular speed in a case where a surface area of the mold is converted into a reference surface area on the basis of information on the surface area of the mold.
19:
- The pouring apparatus according to claim 17, comprising:
- a horizontal movement mechanism configured to drive the ladle in a first direction that is a horizontal direction for approaching and separating from a mold;
- a lifting mechanism configured to drive the ladle in a second direction that is a vertical direction;
- a rotation mechanism configured to rotate the ladle around a rotation axis that is parallel to a third direction orthogonal to the first direction and the second direction, and that passes through a center of gravity of the ladle;
- and
- a distribution calculation unit configured to calculate an amount of operation of the horizontal movement mechanism, the lifting mechanism, and the rotation mechanism to acquire required tilt angular speed calculated by the controller.
20:
- The pouring apparatus according to claim 19, wherein
- the molten metal pouring pattern includes information showing change in virtual tilt angular speed with elapsed time corresponding to at least an initial reaching time step, a stationary time step, a stable waiting time step, and an instruction region step, and
- the controller calculates virtual tilt angular speed according to each of the initial reaching time step, the stationary time step, the stable waiting time step, and the instruction region step.