Responsive To Material Level Patents (Class 164/155.2)
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Patent number: 10537936Abstract: An apparatus for introducing a melt into a casting chamber for a die casting operation has a tundish with an inner volume that can be filled with the melt. A method is provided for filling, by way of the apparatus, the melt into the casting chamber for the die casting operation.Type: GrantFiled: August 21, 2017Date of Patent: January 21, 2020Assignee: Bayerische Motoren Werke AktiengesellschaftInventors: Lucas Schulte-Vorwick, Christian Hirsch
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Patent number: 10369624Abstract: A control method and apparatus for continuous casting steel pouring are provided, wherein the amount of the molten steel flow of the ladle is controlled, thereby improving the yield of the molten steel and decreasing the production cost.Type: GrantFiled: December 10, 2012Date of Patent: August 6, 2019Assignee: Baoshan Iron & Steel Co., LTDInventors: Anxiang Tang, Lifeng Shentu, Jikang Hu, Dean Cao, Xingyu Wang, Chen Chen, Jianqing Yao, Xinghua Lu, Jinsong Chen, Aiping Feng, Xiaoguang Yu
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Patent number: 10307820Abstract: A suction pressure casting method uses a casting device that includes a holding furnace for accumulating molten metal, a metal mold and a core forming a cavity, a molten-metal pressurizing tank that supplies a pressurizing gas, and a suction and exhaust tank for sucking and exhausting the inside of the cavity. A preset decompression pattern of a casting process is compared with a measured pressure pattern of the cavity and the core that is measured during actual casting. A corrected decompression pattern is calculated based on a difference therebetween. The preset decompression pattern at the time of the next casting is then corrected by using the corrected decompression pattern.Type: GrantFiled: May 22, 2015Date of Patent: June 4, 2019Assignee: Nissan Motor Co., Ltd.Inventors: Hidetoshi Shiga, Shinnichi Tsuchiya, Tatsuya Masuta, Kenji Hayashi
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Publication number: 20140262119Abstract: Automated processes that dynamically control rate of delivery of molten metal to a mold during a casting process. Such automated processes can use dynamic metal level variation, control pin pulses and/or oscillation during the mold fill and transient portion of the cast. It has been found that such pulses keep metal flowing in a manner that addresses problems, particularly at the beginning of an ingot cast, associated with metal meniscus contracting and pulling away from the mold on the short faces and corners.Type: ApplicationFiled: March 11, 2014Publication date: September 18, 2014Applicant: Novelis Inc.Inventors: Robert Bruce Wagstaff, David Sinden
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Patent number: 8387678Abstract: A mold system and method for producing a casting. The mold system utilizes multiple channels, each channel comprising a sprue and gating system, to feed the mold cavity at different heights. When a lower portion of the mold is filled, a controller is signaled to initiate filling of the mold through a second channel positioned above the lower portion. This mold system desirably provides the hottest molten metal to the last portion of the casting to freeze with or without the use of risers, eliminating casting defects. The system also enables the controlled pouring of dissimilar metal castings.Type: GrantFiled: November 18, 2011Date of Patent: March 5, 2013Assignee: General Electric CompanyInventors: Junyoung Park, Jason Robert Parolini, Jon Conrad Schaeffer
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Patent number: 7900687Abstract: This invention relates to apparatus and methods for molding battery group straps. Molding apparatus, generally indicated at (10), includes a centrally cooled mold block (11) which defines two laterally displaced sets (12, 13) of longitudinal spaced mold cavity (14) and respective lead feed block (15) and (16) having appropriate feed channels. A sensor, in the form of an electrically conducting rod (25), is disposed so that its tip forms one part of the bottom of the mold cavity (14). This can detect as soon as lead enters into the cavity and that detection is used to control the pour time for the lead to a predetermined period, so that the lead entering the cavities is of a constant quantity on each cycle.Type: GrantFiled: April 3, 2007Date of Patent: March 8, 2011Assignee: TBS Engineering LimitedInventors: Robert T. Hopwood, Simon A. Britton
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Patent number: 7828043Abstract: A level sensing system and method for determining the level of a conductive material in a casting mold are disclosed, wherein the level sensing system a drive circuit and an inductive component disposed adjacent to the casting mold, and a position of the conductive material in the casting mold may be determined by a change in an electrical characteristic of the drive circuit.Type: GrantFiled: October 9, 2007Date of Patent: November 9, 2010Assignee: GM Global Technology Operations, Inc.Inventors: Brian M. Foley, Scott W. Biederman, Reinhold Ludwig, Sergey Makarov
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Publication number: 20090218069Abstract: This invention relates to apparatus and methods for moulding battery group straps. Moulding apparatus, generally indicated at (10), includes a centrally cooled mould block (11) which defines two laterally displaced sets (12, 13) of longitudinal spaced mould cavity (14) and respective lead feed block (15) and (16) having appropriate feed channels. A sensor, in the form of an electrically conducting rod (25), is disposed so that its tip forms one part of the bottom of the mould cavity (14). This can detect as soon as lead enters into the cavity and that detection is used to control the pour time for the lead to a predetermined period, so that the lead entering the cavities is of a constant quantity on each cycle.Type: ApplicationFiled: April 3, 2007Publication date: September 3, 2009Applicant: TBS ENGINEERING LIMITEDInventors: Robert T. Hopwood, Simon A. Britton
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Publication number: 20080169080Abstract: A casting mould for manufacturing a cast part from a metal melt includes a mould cavity for reproducing a cast part and comprising an inlet for pouring metal melt into the mould cavity and also to a device and a process for casting metal melts of this type. The casting mould provides further optimized casting results even under hard practical operating conditions. In addition, the use or application of the device according to the invention and the process minimizes the risk of jamming during casting. This is achieved in that the casting mould has at least one compensation chamber which is linked to the mould cavity via a channel and comprises at least one portion which is arranged above the maximum filling level (Fmax) of the casting mould during solidification of the metal melt.Type: ApplicationFiled: February 22, 2006Publication date: July 17, 2008Inventors: Klaus Lellig, Michael Stolz
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Patent number: 7011137Abstract: The molding device comprises a lower mold unit and an upper mold unit. When the upper mold unit approaches the lower mold unit, a molding cavity is defined between the lower and upper mold units. The lower mold unit has a storing chamber that is communicated with the molding cavity. The lower mold unit comprises a pressure-decreasing mechanism and a pushing mechanism. A molten material is stored in the storing chamber. When the molding cavity is formed between the lower mold unit and the upper mold unit, the pressure-decreasing mechanism decreases pressure in the molding cavity. Afterwards, in sync with the operation that the upper mold unit pushing down a lower mold-holding member of the lower mold unit, an injection rod of the pushing mechanism pushes out the molten material in the storing chamber to the molding cavity. As a result, the efficiency of the molding operation is improved.Type: GrantFiled: April 14, 2003Date of Patent: March 14, 2006Assignee: Toshihara Kanagata Kogyo Co., LTDInventor: Akira Itoh
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Patent number: 6896032Abstract: A casting apparatus for pouring molten metal into molds comprises a vessel having a molten metal-receiving chamber generally extending between a filling end and a pouring end. The vessel includes a nozzle disposed in a bottom surface of the chamber proximate to the pouring end. A stopper cooperates with the nozzle to control a downward gravity flow of molten metal through the nozzle. A first support pivotably supports the vessel to provide a horizontal tilt axis substantially coincident with the nozzle. A second support is connected to the vessel at a point away from the tilt axis and has a drive for controlling a pivot position of the vessel. A tilt angle controller detects a level of molten metal within the chamber and engages the drive to maintain the level at a predetermined level.Type: GrantFiled: September 26, 2002Date of Patent: May 24, 2005Assignee: Hayes Lemmerz International, Inc.Inventors: Daniel D. Minor, Mark Salgat, William W. Seaton, David Good, Kenneth D. McKibben
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Patent number: 6892791Abstract: A casting apparatus for pouring molten metal into molds comprises a vessel having a molten metal-receiving chamber generally extending between a filling end and a pouring end. The vessel includes a nozzle disposed in a bottom surface of the chamber proximate to the pouring end. A stopper cooperates with the nozzle to control a downward gravity flow of molten metal through the nozzle. A first support pivotably supports the vessel to provide a horizontal tilt axis substantially coincident with the nozzle. A second support is connected to the vessel at a point away from the tilt axis and has a drive for controlling a pivot position of the vessel. A tilt angle controller detects a level of molten metal within the chamber and engages the drive to maintain the level at a predetermined level. A horizontal support rail slidably supports the vessel to provide a horizontal movement perpendicular to the tilt axis.Type: GrantFiled: December 20, 2002Date of Patent: May 17, 2005Assignee: Hayes Lemmerz InternationalInventors: Daniel D. Minor, Mark Salgat, William W. Seaton, David Good, Kenneth D. McKibben
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Patent number: 6868861Abstract: A level control system for controlling the thickness of a work material in a slurry form cast upon a moving belt includes a fluid reservoir disposed above the belt, a sensor lens assembly for sensing the slurry height within such reservoir, and a control valve for adding slurry to the reservoir. A lens disposed near the moving belt and above the reservoir is coupled by fiber optics to a remote sensor amplifier for detecting the height of the slurry. A control circuit responsive to the light sensor regulates the flow rate of the slurry through the control valve.Type: GrantFiled: November 6, 2001Date of Patent: March 22, 2005Assignee: Credence Engineering, Inc.Inventor: James Edward Ellis
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Patent number: 6761209Abstract: A method is described of operating a hot-chamber pressure diecasting machine and a pressure diecasting machine suitable for the implementation of this method, by which a prefilling of the casting system can be carried out before the actual mold filling operation. During this prefilling operation, the air present in the casting system after each shot when the casting plunger is withdrawn, is pressed out during this prefilling operation through the mold which is still open during this time period. This amount of air therefore no longer has to escape during the subsequent mold filling operation. The mold filling operation and the pressing-in operation can therefore be implemented more effectively and within a shorter period of time.Type: GrantFiled: August 8, 2002Date of Patent: July 13, 2004Assignee: Oskar Frech GmbH & Co.Inventor: Ronald Fink
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Patent number: 6588493Abstract: A model-based strategy is provided for determining casting roll operating temperature in a continuous thin strip casting process. A first temperature sensor produces a first temperature signal indicative of the temperature of cooling liquid supplied to the casting rolls and a second temperature sensor produces a second temperature signal indicative of the temperature of cooling liquid temperature exiting the casting rolls. A computer determines a heat flux value as a function of the first and second temperature signals, and computes the operating temperature of the casting rolls as a function of the heat flux value, the second temperature signal and a number of constants defined by fixed-valued operating parameters of the continuous thin strip casting process. A control strategy is also provided to modify one or more operating parameters of the continuous thin strip casting process as a function of the casting roll temperature.Type: GrantFiled: December 21, 2001Date of Patent: July 8, 2003Assignee: Nucor CorporationInventors: Walter Bleide, Rama Mahapatra
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Patent number: 6581673Abstract: A method for producing a cast article comprising the steps of: (a)providing a casting apparatus having a mold, a casting chamber containing a molten metal under pressure and a fluid under pressure, the casting apparatus having a first supply port for supplying the molten metal to the casting chamber and a second supply port for supplying the fluid to the casting chamber; (b) supplying the molten metal to the first supply port; (c) supplying the fluid to the second supply port; (d) determining the amount of the molten metal in the casting chamber as a variable V1; (e) determining the amount of the fluid in the casting chamber as a variable V2; (f) determining the amount of humidity in the casting chamber as a variable V3; (g) determining the amount of the fluid entering the casting chamber as a variable V4; (h) determining the pressure of the fluid in the casting chamber as a variable V5; (i) determining the amount of the molten metal needed to produce a cast article in the mold as a variable V6; (j) determiniType: GrantFiled: December 29, 2000Date of Patent: June 24, 2003Assignee: Hayes Lemmerz International, Inc.Inventors: Kenneth D. McKibben, Daniel D. Minor, Robert L. Macheske, David B. Good, Thomas J. Rozich, Mark Salgat, Brandon Schnettler
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Patent number: 6557619Abstract: For improvement in production efficiency by elimination of a centering of an ingot supplier to an ingot supply opening upon reconnection of a melting and holding furnace to a die cast machine, there are provided an intermediate handler having a receiving case configured substantially in a channel shape open at both ends thereof, and pivoted on the furnace cover to be movable between a substantially horizontal lying position with one end thereof coincident with an ingot exit of the preheater to allow for a preheated ingot to be forward therein in a lying position with a longitudinal axis thereof set substantially horizontal and a substantially vertical standing position with the other end thereof coincident with the ingot supply opening to bring a distal end of the preheated ingot forwarded therein into abutment with the shutter to make the preheated ingot stand thereon, and an ingot supplier having a pawl chuck configured to enter inside the receiving case from an open side of the receiving case in the substaType: GrantFiled: November 28, 2001Date of Patent: May 6, 2003Assignee: Toshiba, Kikai Kabushiki KaishaInventor: Shinichi Katoh
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Patent number: 6513571Abstract: A low pressure casting machine having a fill line connected between a thermally insulated chamber and a refractory furnace. A solenoid valve is included in the fill line and is selectively opened to allow gravity to fill the thermally insulated chamber to a predetermined level with molten metal. The thermally insulated chamber is subsequently pressurized to force molten metal from the chamber into a mold cavity to cast a metal component.Type: GrantFiled: May 27, 1999Date of Patent: February 4, 2003Assignee: Hayes Lemmerz International, Inc.Inventor: Romulo A. Prieto
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Patent number: 6505677Abstract: When casting metal articles in a mould by forcing molten metal upwardly through a filling tube by gas pressure in a closed chamber, the datum level just below that of a connector connecting the filling tube to the mould is registered by a level sensor in a sensing tube while the latter's upper end is connected to atmosphere through a vent tube. At the same moment, the pressure is measured by a pressure sensor and recorded by a control unit and maintained constant by the latter after the emptying of the sensing tube, by connecting its upper end to the chamber through an equalizing tube, until the pressure is increased to fill the mould according to a predetermined function of time programmed into the control unit. The starting point for the filling of all moulds in succession is the same, regardless of the amount of metal in the supply unit.Type: GrantFiled: November 6, 2000Date of Patent: January 14, 2003Assignee: Georg Fischer Disa A/SInventors: Peter MĀ„ller Iversen, Uffe Andersen
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Patent number: 6467532Abstract: When casting e.g. aluminium alloy in a mould (2), that may be one of a string of moulds extending at right angles to the plane of the drawing, the pressure used for filling the mould (2) against gravity by a pressurizing device (4) is controlled according to a predetermined pressure/time programme having previously been read into a control unit (22), e.g. a digital computer, at least one of a number of sensors sensing pressure (8), levels (9,10) and full level (11) being used to supply inputs to the control unit (22). Sensors are chosen according to need for each particular casting programme.Type: GrantFiled: December 18, 2000Date of Patent: October 22, 2002Assignee: Georg Fischer Disa A/SInventors: Henrik Klarskov Andersen, Kaj J. Jensen, Henning Larsen
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Patent number: 6341640Abstract: In casting metal objects in casting cavities (2) in moulds (1), connectable to a pressurized mould-filling furnace (5) through a delivery tube (8) and a connector (9), an external riser (13) is connected to and extends upwardly from the junction of the tube (8) and the connector (9). The riser (13) is used as a temporary reservoir in which the level of molten metal is regulated by controlling the gas pressure in space 7 in the furnace (5) such that the filling head, defined as the difference in level between the metal in the casting cavities (2) and that in the external riser (13), is kept constant or made to vary in a desired manner, e.g. so as to cause the level in the cavities to ascend at a substantially constant rate. The invention makes it inter alia possible to produce high-quality aluminum castings in sand moulds, e.g. using automatic foundry equipment of the DISAMATIC® type.Type: GrantFiled: December 22, 1999Date of Patent: January 29, 2002Assignee: Georg Fischer Disa A/SInventors: Peter Iversen, Uffe Andersen
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Patent number: 6334975Abstract: 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.Type: GrantFiled: October 25, 1999Date of Patent: January 1, 2002Assignee: Toshiba Kikai Kabushiki KaishaInventors: Hironori Yokote, Kazuhiro Suzuki, Yukio Katou