Automatic ingot unloading device and method

Abstract

A device for automatically discharging ingots from a stack of ingots is disclosed that includes a frame, a lift device positioned within the frame, a platform rotatably coupled to the lift device, and a discharge mechanism coupled to the frame. The automatic ingot discharging device of the present invention is utilized to reduce the time and labor required to move ingots from one location to another in a casting facility, and thus, increase the production efficiency for manufacturing cast objects.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to transport systems. More particularly, the present invention is directed to methods and devices for automatically discharging ingots from a stack of ingots.

BACKGROUND OF THE INVENTION

[0002] In the casting industry, a metal object is created from the solidification of molten metal in a mold that defines the shape of the object. The metal typically arrives at a casting facility in the form of solid metal bars, generally referred to as ingots, that are stacked on a palette in the manner shown in FIG. 1.

[0003] Prior to formation of a metal object, the ingots have to be removed from the stack 10 and carried to a furnace where the ingots are heated to the molten state required for injection into the mold. Where a melt system is employed at a casting facility, the ingots are, typically, placed on a conveyor; at the end of the conveyor, the ingots fall off into a bucket; and the bucket drops the ingots into a furnace where the ingots are heated. As the ingots melt, the metal trickles into a bath, where a ladle dips out an amount of the molten metal for injection into a mold.

[0004] Shown in FIG. 1(b), is an exemplary ingot 12 that is about twenty-eight inches long, and approximately thirty pounds in weight. To remove the ingots from the stack, a significant amount of manual labor and time is utilized to lift and carry the ingots from one location to another.

[0005] Thus, the operator of the casting equipment has to stop the equipment, while ingots are being loaded, for example on the conveyor of the melt system. Accordingly, the production of objects is delayed.

[0006] In addition, the amount of melt in the bath varies significantly between drops of ingots into the furnace. During the time between drops of metal into the melt system, the die cast parameters (i.e., the conditions required of the metal before it is deposited in a mold), such as metal temperature, shot weight, and metal cleanliness may fluctuate. Accordingly, the die cast parameters have to be constantly monitored, and adjustments to the casting equipment have to be performed to keep the metal within the desired die cast parameters.

[0007] Further, the exemplary ingot of FIG. 1(b) has a trapezoidal structure. As with any trapezoidal structure, the top width 14 of the trapezoidal structure is shorter than the bottom width 16 of the trapezoidal structure.

[0008] Referring back to FIG. 1(a), it is shown that the top width 14 of an ingot is smaller than the bottom width 16 of the ingot. Thus, the tops 14 of the ingots, when placed side by side, do not meet. Accordingly, after a first layer of ingots has been placed on a palette with their bottoms 16 down, the following layer of ingots is formed by inverting the ingots, such that tops 14 of the next layer of ingots fit within the openings between the tops 14 of the ingots of the previous layer (i.e., the bottoms of the ingots are at the top), and a reciprocating row 18 of ingots is formed.

[0009] To form the next reciprocating stack of ingots, the ingots are usually laid perpendicular to the previous reciprocating stack, in the direction of arrows 20. Thus, all of the ingots in a stack are not aligned in the same direction. An additional amount of manual labor and time is needed to rotate the ingots, such that the ingots can be easily removed from the stack.

[0010] Accordingly, it would be desirable to provide a system and method for automatically unloading ingots from a stack that increases the efficiency of producing casted objects, and reduces the amount of manual labor utilized to transport the ingots. Further, it would also be desirable to provide a method and system for rotating the ingots, so that the ingots are oriented in a desirable direction for removal from a stack.

[0011] In addition, it would be desirable to provide a system and method for automatically unloading ingots that reduces the amount of monitoring of the metal in the bath, and the amount adjusting of the casting equipment to maintain the desired die cast parameters.

SUMMARY OF THE INVENTION

[0012] In one aspect of the invention, an apparatus for transferring ingots from a stack of ingots is provided that includes a frame, a lift device positioned within the frame, a platform rotatably coupled to the lift device, and a discharge mechanism, coupled to the frame, that pushes ingots from the stack of ingots.

[0013] In another aspect of the present invention, the platform rotates the stack of ingots by at least ninety degrees.

[0014] In another aspect of the present invention, a system for transferring ingots from a stack of ingots is provided that includes a means for lifting the stack of ingots, a means for rotating the stack of ingots, which is coupled to the rotating means, and a means for discharging the ingots from the rotating means.

[0015] In yet another aspect of the present invention, a method is provided for transferring ingots from a stack of ingots that includes pushing a first layer of ingots from the stack of ingots, lowering the stack of ingots, rotating the stack of ingots ninety degrees, and discharging a second layer of ingots from the stack of ingots.

[0016] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended hereto.

[0017] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

[0018] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

BRIEF DESCRIPTION OF THE FIGURES

[0019] FIG. 1(a) illustrates ingots on a palette.

[0020] FIG. 1(b) illustrates an ingot.

[0021] FIG. 2 is an automatic ingot unloading device in accordance with the present invention.

[0022] FIG. 3 illustrates operation of an automatic ingot unloading device in accordance with the present invention.

[0023] FIG. 4 is a block diagram of an automatic ingot unloading device, in accordance with the present invention, that is included in a melt system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0024] Referring now to the figures, wherein like reference numerals indicate like elements, in FIG. 2, there is shown an automatic transfer apparatus 22 in accordance with the present invention. For purposes of example, the transfer apparatus 22 is described as an apparatus for lifting a stack of ingots 10, and automatically discharging the ingots 16 from the stack. However, the transfer apparatus 22 of the present invention may be utilized for lifting and/or discharging any load.

[0025] In a preferred embodiment of the present invention, the transfer apparatus 22 includes a platform 24 for positioning a palette of a stack of ingots, such as the stack of ingots 10 shown in FIG. 1(a). The platform 24 is rotatably coupled to a lift device 26, such that the orientation of the stack of ingots 10 is variable. In an exemplary embodiment of the present invention, the platform 24 is stationary and the lift device 26 rotates, such that the orientation of the stack of items may be varied. In another exemplary embodiment of the present invention, the platform rotates and the lift device 26 is stationary. In yet another exemplary embodiment of the present invention, the platform 24 and the lift device 26 rotate.

[0026] In the preferred embodiment of the present invention, the lift device 26 is coupled to a base 28. Alternatively, the lift device 26 extends through a port or opening in the base 28.

[0027] The lift device may operate, for example via hydraulics, pneumatics, or electromechanical methods known in the art. A Pro Series Lift and Rotate Table by PENTALIFT™ of Buffalo, N.Y. may be utilized for the platform 24 and lift device 26.

[0028] A frame 30 is coupled to the base 28, and defines the space for inserting and positioning a stack of ingots 10. In the preferred embodiment of the present invention, the base 28 and frame 30 are made from a metal and welded together. However, it should be understood by one of ordinary skill in the art that the base 28 and frame 30 may be constructed from other materials. It should also be understood by one of ordinary skill in the art that the frame 30 and/or base 28 are optional, but provide rigidity.

[0029] In the preferred embodiment of the present invention, the design of the frame 30 includes a first pair 32 of vertical members, which includes a front 36 and rear 38 member, connected to each other via a first upper member 40, and a second pair 42 of vertical members, which includes a front 44 and rear 46 member, connected to each other via a second upper member 48. A third upper member 50 is provided for connecting the front members 36, 44 of each of the first and second pair of vertical members 32, 42, and a fourth upper member 52 is provided for connecting the rear vertical members 38, 46 of each of the first and second pair of vertical members 32, 42.

[0030] In the preferred embodiment of the present invention, a discharge surface 54, for example, a slide or conveyor, is coupled to the third upper member 50. The discharge surface may be permanently, via, for example a welded joint, or removeably coupled to the third upper member 50. It should be understood by one of ordinary skill in the art that the discharge surface 54 is not essential to the operation of the present invention.

[0031] Coupled to the first upper member is a first electric motor 56 that operates to push a first pushing member 58, and coupled to the second upper member 48 is a second electric motor 60 that operates to push a second pushing member 62.

[0032] Each of the first and second upper members 40, 48 includes a groove 64, and the first and second pushing members 58, 62 are slidably engaged with each groove 64. In a preferred embodiment of the present invention, the pushing members 58, 62 are coupled to the motors via, a connecting member, for example, a chain or cord, and the pushing members 58, 62 slide within the corresponding groove by a distance corresponding to the amount of the connecting member that is released by each motor 56, 60.

[0033] In another exemplary embodiment of the present invention, a single discharge mechanism is utilized to push the ingots 16 from a stack 10. Alternatively, the discharge mechanism could operate by pushing devices, for example, hydraulic or pneumatic cylinders.

[0034] The hydraulic or pneumatic pushing devices may be positioned in a direction perpendicular to the third upper member 50, and utilized to push the ingots 16, which may be positioned, for example, in a similar direction, from the stack 10. The hydraulic or pneumatic pushing devices may provide a sufficient amount of force to push ingots 16, which, for example, may be shaped in a manner that does not allow the ingots 16 to easily slide off of the underlying layer of ingots 16 onto a discharge surface 54.

[0035] Typically, seven ingots 16 make up one layer of ingots 16. In an exemplary embodiment of the present invention, seven hydraulic or pneumatic pushing devices are positioned in a fixed location for pushing each of the seven ingots 16 from the stack 10. In an exemplary embodiment of the present invention, the seven ingots 16 are positioned parallel, lengthwise, to the pushing devices, and each pushing device independently pushes one of the seven ingots 16 from the stack 10.

[0036] In another exemplary embodiment of the present invention, the seven ingots are positioned parallel, lengthwise, to a single pushing device, and the single pushing device moves along an axis perpendicular to the ingots 16 to individually push each ingot 16 form the stack 10.

[0037] In another exemplary embodiment of the present invention, the seven ingots 16 are positioned parallel, lengthwise, to a single pushing device that pushes, at one time, the seven ingots from the stack 10. It should be understood by one of ordinary skill in the art that the number of ingots 16 per layer may vary.

[0038] During operation of the transfer apparatus 22 of the present invention, as shown in FIG. 3, the lift device 26 elevates a stack of ingots 10 until the first layer of the stack is positioned above the third upper member 50, such that the ingots 16 of the first layer may be discharged. The third upper member retains the second layer of ingots 16 in their position.

[0039] The pushing means 58, 62 operate to push on the rear of the first layer, such that the desired number of ingots is automatically discharged from the stack of ingots 10 onto the discharge surface 54.

[0040] When a layer of ingots rises to the top of the stack, 10 having ingots 16 that are stacked, for example in a direction that is not parallel to the third upper member 50, the platform 24 is lowered to a position where the frame 30 will not interfere with the rotation of the stack of ingots 10. The platform 24 is then raised again to the position, where the pushing members 58, 62 may operate to discharge the ingots 16 from the stack of ingots 10.

[0041] In another exemplary embodiment of the present invention, the platform 24 is raised to rotate the stack of ingots 10, and then lowered to a discharging position.

[0042] In another exemplary embodiment of the present invention, where there is no frame 20, or where the frame 30 is designed not to interfere with the rotation of the stack of ingots 10, the platform 24 is not raised or lowered prior to rotation.

[0043] When the stack of ingots 10 includes layers that are stacked in a direction that is parallel to the first and second upper members 40, 48, the platform 24 is rotated ninety degrees to orient the stack of ingots 10 in a direction that is perpendicular to the first and second upper members 40, 48 (and thus, parallel to the third upper member 50), to allow the first and second pushing members 58, 62 to discharge the ingots 16 from the stack of ingots 10.

[0044] The transport apparatus automatically repeats the above-described process of lifting, discharging and rotating the stack of ingots 10 until all of the ingots 16 have been discharged form the stack 10. Accordingly, less manual labor and time is required to transport the ingots 16 from one place to another.

[0045] A controller 66 is electrically coupled to the lift device 26 and the discharge mechanism, which may be pushing members 58, 62, for example, via the motor 56, to control the lifting and pushing operations of the transfer system 22. The controller 66 may also be coupled to a discharge surface 54, such as an electromechanical conveyor, to automatically control the rate at which the ingots 16 move along the conveyor. The controller 66 may be electrically coupled to the transfer system 22 via conductive devices or radio frequency methods.

[0046] Shown in FIG. 4, the transfer system 22 of the present invention is part of a melt system 68. The melt system 68 includes the transfer apparatus 22, with or without the discharge apparatus 54, a conveyor 70, a bucket 72, a furnace 74 and a bath 76. When the transfer apparatus 22 is placed in the melt system 68, the casting machines do not have to be stopped to load ingots 16 onto the conveyor 70 of the melt system 68. Accordingly, more objects can be manufactured in a certain time frame, and the production of objects is more efficient.

[0047] Further, there is a continuous deposit of metal into the bath 76. Accordingly, a constant level of molten metal can be maintained for the making of objects. In addition, the die parameters do not significantly vary because the time frame, during which the die parameters could fluctuate, is reduced. Accordingly, the die parameters of the metal can be monitored less, and the adjusting of the casting machinery to maintain the die parameters may also be less.

[0048] The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Claims

1. An apparatus for transferring ingots from a stack of ingots, comprising:

a frame;

a lift device positioned within the frame;

a platform rotatably coupled to the lift device; and

a discharge mechanism that pushes the ingots from the stack of ingots, said discharge mechanism coupled to the frame.

2. The apparatus of claim 1, where the platform is configured to rotate ninety degrees clockwise or counterclockwise.

3. The apparatus of claim 1, further comprising:

a base coupled to the frame.

4. The apparatus of claim 3, wherein the lift device is coupled to the base.

5. The apparatus of claim 1, further comprising a first motor coupled to the discharge mechanism.

6. The apparatus of claim 6, further comprising a connecting member coupled between the motor and the discharge mechanism.

7. The apparatus of claim 1, wherein the discharge mechanism is at least one of a hydraulic discharge mechanism and a pneumatic discharge mechanism.

8. The apparatus of claim 1, wherein the lift device is at least one of a hydraulic lift device, and a pneumatic lift device.

9. The apparatus of claim 1, wherein the frame comprises:

a first pair of vertical members connected via a first upper member; and

a second pair of vertical members connected via a second upper member.

10. The apparatus of claim 9, wherein the first pair of vertical members comprises:

a first front vertical member; and

a first rear vertical member,

and wherein the second pair of vertical members comprises:

a second front vertical member; and

a second rear vertical member.

11. The apparatus of claim 10, wherein the first upper member includes a first groove, and the second upper member includes a second groove.

12. The apparatus of claim 11, wherein the discharge mechanism is slidably positioned between the first groove and second groove.

13. The apparatus of claim 11, wherein the discharge mechanism comprises:

a first pushing member; and

a second pushing member.

14. The apparatus of claim 13, wherein the first pushing member is slidably positioned within the first groove and the second pushing member is slidably positioned within the second groove.

15. The apparatus of claim 1, further comprising: a discharge surface coupled to the frame.

16. The apparatus of claim 15, wherein the discharge surface is at least one of a slide and a conveyor.

17. A system for transferring ingots from a stack of ingots, comprising:

means for lifting the stack of ingots;

means for rotating the stack of ingots, said rotating means coupled to the lifting means; and

means or discharging the ingots from the rotating means.

18. The apparatus of claim 17, wherein the rotating means rotates the ingots by ninety degrees.

19. A method for transferring ingots from a stack of ingots, comprising:

discharging ingots from a first a layer of ingots in the stack of ingots;

rotating the stack of ingots ninety degrees; and

discharging the ingots from a second layer of ingots of the stack of ingots.

20. The method of claim 19, further comprising:

lowering the stack of ingots after discharging the first layer of ingots; and

raising the stack of ingots before discharging the ingots from the second layer of ingots.

21. The apparatus of claim 1, wherein the discharge mechanism comprises seven pushing members.