Mold Handling System

Abstract

A mold handling manufacturing line, which includes at least a first subline and a second subline, is provided. The mold handling manufacturing line moves at least one mold car that supports a cast mold, which forms a cast part, the mold handling manufacturing line comprising at least a first subline and a second subline and a first transfer station. The second subline is located substantially parallel with and spaced apart from the first subline. The first transfer station in communication with the first subline and the second subline. The first transfer station includes a transfer cart configured to receive the at least one mold car. The first transfer station includes a servo belt driven line composed of a servo motor rotates one or more drive pulleys, via a belt. which is coupled to the transfer cart. When the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the first subline and the second subline. Also, when the servo motor rotates in a second rotational direction, it causes the belt, positioned on the one or more drive pulleys, to move the transfer cart in a second linear direction between the first subline and the second subline.

Description

RELATED APPLICATIONS

The present Application relates to and claims priority to U.S. Provisional Patent Application, Ser. No. 63/470,586, filed on Jun. 2, 2023, entitled “Mold Handling System.” The subject matter disclosed in that Provisional Application is hereby expressly incorporated into the past Application.

TECHNICAL FIELD AND SUMMARY

The present disclosure relates to a cast part manufacturing line and, in particular, to a mold handling system that moves mold cars along the manufacturing line in an improved manner.

Cast parts, particularly those made from molten metal, such as water valves, couplings, etc., are often formed in a sand mold. This sand mold is typically composed of two halves that each form half an image of the folded part. When the two halves are joined, their images form a cavity in the shape of the fully molded part. A passageway extends from the cavity to the exterior of the sand mold. This allows molten metal to be poured into the sand mold to form the part. Once this occurs, the molten metal is allowed to cool and solidify. Once the part solidifies, it is removed from the sand mold, typically for further processing. The sand mold is destroyed and the sand recycled to create a new sand mold for another part.

The cast part manufacturing line is a known way of mass-producing such parts. This manufacturing line includes a first station where the mold is created, a second station where molten metal is poured into the mold, and a third station where the cast part is removed and the sand recycled. In order to transport the sand mold to and between stations, the sand mold is placed on a mold car that travels along a rail line. In addition to traveling between these stations, the rail line accommodates the need for the molten metal to solidify and cool. This takes time. Accordingly, the rail line creates an extended path, particularly between the station where the molten metal is poured and where the cast part is removed. The mold cars are moved along this rail line via two mechanisms—an adjacent mold car or an actuator. With the rail line substantially full of mold cars lined up one after another, when one mold car is moved, it pushes its adjacent mold car, which pushes another adjacent mold car, and so on. This creates a chain reaction of constantly moving or indexing mold cars. Additionally, the rail line can be split into multiple sublines to conserve space on a manufacturing floor. Actuators are used to both move a mold car from one subline to another, as well as move a mold car onto the subline and initiate moving an adjacent mold car.

Multiple transfer stations connect the multiple sublines. An actuator at a transfer station moves the mold car from one subline to another subline. Another actuator then moves that mold car from the transfer station and onto the subline. When this happens, the mold car being moved onto the subline pushes an adjacent mold car, which pushes another adjacent mold car. This creates the chain reaction causing each mold car on the subline to move (or index) one position. At the end of the subline, the last mold car is pushed onto another transfer station by an actuator that moves it to the next subline. And again, another actuator moves that mold car off of the transfer station and onto this new subline. And again, that mold car pushes an adjacent mold car, which pushes another adjacent mold car. This process continues throughout all of the manufacturing line.

Such a manufacturing line may include more than 100 mold cars, each being actively indexed along the sublines at any given time. It is contemplated that the time it takes to move the mold car, particularly between pouring the molten metal into the mold and the cast part removed, is sufficient to allow that part to cool and solidify.

An issue with such manufacturing lines is that the sand molds are relatively fragile. As the mold cars are moved between sublines and against each other while indexing along the sublines, the shape of the cavity can be damaged both before and after the molten metal is poured into the sand mold. Sudden starts, stops, and impacts may cause one half of the sand mold to shift with respect to the other half. This creates a risk that the integrity of the shape of the molded cavity and, thus, the molded part becomes damaged.

A potential reason for this sudden start and stop is because of how the actuators operate and move the mold cars. These actuators are hydraulically driven, which creates a relatively immediate start and immediate stop. Because of this, there is a potential for one-half of the mold to stop or start quicker than the other half of the mold (see FIGS. 2-8). The mold car's sudden starts and stops, when being moved by these actuators, can shift the sand and damage the part.

Accordingly, an illustrative embodiment of the present disclosure provides a mold handling manufacturing line which comprises a first subline; a second subline, a third subline, a fourth subline, a first transfer station, and a second transfer station. The second subline is located substantially parallel with and spaced apart from the first subline. The third subline is located substantially parallel with and spaced apart from the first subline and the second subline. The fourth subline is located substantially parallel with and spaced apart from the first subline, the second subline, and the third subline. The first transfer station is in communication with the fourth subline and the first subline and includes a transfer cart configured to receive the at least one mold car. The first transfer station includes a servo belt driven line composed of a servo motor that is about centrally located with respect to the first transfer station and rotates one or more drive pulleys via a belt; the belt is coupled to the transfer cart; when the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the fourth subline and the first subline; and when the servo motor rotates in a second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a second linear direction between the fourth subline and the first subline. The second transfer station is located distal from the first transfer station. The second transfer station is in communication with the first subline, the second subline, the third subline, and the fourth subline, and includes a first transfer cart configured to receive the at least one mold car and a second transfer cart configured to receive another at least one mold car. A servo actuator, as part of the second transfer station, moves a rod in the first linear direction and the second linear direction. The rod is attached to the first transfer cart of the second transfer station and the second transfer cart of the second transfer station so that the first transfer cart of the second transfer station and the second transfer cart of the second transfer station are movable in the first linear direction and the second linear direction, together, as the rod correspondingly moves in the first linear direction and the second linear direction. This moves the first transfer cart of the second transfer station between the first subline and the second subline and the second transfer cart of the second transfer station between the third subline and the fourth subline.

In the above and other embodiments, the mold handling manufacturing line may further comprise: the one or more drive pulleys of the first transfer station includes a first pulley and a second pulley, wherein the first pulley is spaced apart from the second pulley and spans a distance that is at least a length of travel of the first transfer cart; when the servo motor rotates in the first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in the first linear direction to the fourth subline, when the servo motor rotates in the second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in the second linear direction to the first subline; an index actuator that operates adjacent the first transfer station and the first subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the transfer cart of the first transfer station is located adjacent the first subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the first transfer station onto the first subline; an index actuator that operates adjacent the first transfer station and the first subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the transfer cart of the first transfer station is located adjacent the first subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the first transfer station onto the first subline; an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline; an index actuator that operates adjacent the second transfer station and the fourth subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein when the second transfer cart of the second transfer station is located adjacent the fourth subline the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the another at least one mold car in order to pull the another at least one mold car from the transfer cart of the second transfer station onto the fourth subline; the servo actuator of the second transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the first transfer cart of the second transfer station and the second transfer cart of the second transfer station attached; the servo actuator of the index actuator rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the indexing block attached; a third transfer station located distal from the second transfer station, wherein the third transfer station is in communication with the second subline and the third subline, wherein the third transfer station includes a transfer cart configured to receive the at least one mold car, wherein a servo actuator, as part of the third transfer station, moves a rod in the first linear direction and the second linear direction, and wherein the rod is attached to the transfer cart of the third transfer station so that the transfer cart of the third transfer station is movable in the first linear direction and the second linear direction as the rod correspondingly moves in the first linear direction and the second linear direction to move the transfer cart of the third transfer station between the second subline and the third subline; the servo actuator of the third transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the third transfer station attached; comprising a jacket lift assembly configured to place a mold jacket over a mold on the at least one mold car, wherein the jacket lift assembly includes one or more jacket lift arms, wherein a servo actuator includes an extendable rod that is attached to a frame, which is attached to the one or more jacket lift arms to extend or retract the one or more jacket lift arms; the servo actuator of the jacket lift assembly rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the frame of the jacket lift assembly attached; further comprising a sand push off station configured to remove the cast mold made of sand from the at least one mold car, wherein the sand push off station includes a jacket lift actuator assembly and a push off actuator assembly, wherein the jacket lift actuator assembly includes a jacket lift servo actuator that is configured to selectively raise and lower one or more jacket lift arms, via a frame, to remove a jacket prior to removing the sand from the cast mold on the at least one mold car, and wherein the push off actuator assembly includes a push off servo actuator that has an extendable rod, which moves the jacket lift actuator assembly so that after the jacket lift actuator assembly lifts the jacket from a mold, the push off servo actuator is configured to move the jacket lift actuator assembly and the mold seated on the at least one mold car; and the push off servo actuator of the push off actuator assembly rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the frame of the push off actuator assembly attached.

Another illustrative embodiment of the present disclosure provides a mold handling manufacturing line which comprises a first subline and a second subline. The mold handling manufacturing line moves at least one mold car that supports a cast mold which forms a cast part, the mold handling manufacturing line comprising at least a first subline and a second subline and a first transfer station. The second subline is located substantially parallel with and spaced apart from the first subline. The first transfer station in communication with the first subline and the second subline. The first transfer station includes a transfer cart configured to receive the at least one mold car. The first transfer station includes a servo belt driven line composed of a servo motor that is about centrally located with respect to the first transfer station and rotates one or more drive pulleys, via a belt, which is coupled to the transfer cart. When the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the first subline and the second subline. Also, when the servo motor rotates in a second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a second linear direction between the first subline and the second subline.

In the above and other embodiments, the mold handling manufacturing line may further comprise: the servo motor of the first transfer station rotates a ballscrew, which linearly moves a rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the first transfer station attached; and an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein when the first transfer cart of the second transfer station is located adjacent the second subline the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline.

Another illustrative embodiment of the present disclosure provides a mold handling manufacturing line, which comprises a first subline, a second subline, and a first transfer station. The second subline is located substantially parallel with and spaced apart from the first subline. The first transfer station is in communication with the first subline and the second subline. The first transfer station also includes a transfer cart configured to receive the at least one mold car. A servo actuator, as part of the third transfer station, moves a rod in a first linear direction and a second linear direction. The rod is attached to the transfer cart of the first transfer station so that the transfer cart of the first transfer station is movable in the first linear direction and the second linear direction as the rod correspondingly moves in the first linear direction and the second linear direction. This moves the transfer cart of the first transfer station between the first subline and the second subline.

In the above and other embodiments, the mold handling manufacturing line may further comprise: the servo actuator of the first transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the first transfer station attached; and an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline.

Additional features of the mold handling system will become apparent to those skilled in the art upon consideration of illustrative embodiments of carrying out the mold handling system as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The concepts described in the present disclosure are illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity, and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, and clarity, the dimensions of some elements may be exaggerated relative to other elements. Further, where considered appropriate, reference labels may be repeated among the figures to indicate corresponding or analogous elements.

FIG. 1 is a downward looking schematic view of a mold or cast part manufacturing line;

FIG. 2 is a side view of a mold car with a mold place thereon;

FIG. 3 is another side view of a mold car with a mold place thereon;

FIG. 4 is a perspective view of a mold sitting on a mold car;

FIG. 5 is a perspective view of a portion of drag and cope portions of the mold;

FIG. 6 is in enlarged perspective view of a portion of the drag and the cope;

FIG. 7 is a side view of a portion of a prior art transfer station on a prior art manufacturing line;

FIG. 8 is a chart depicting relative hypothetical changes in velocity over position between a hydraulic driven actuator and a servo driven actuator;

FIG. 9 is another downward looking schematic view of the cast part manufacturing line;

FIG. 10 is an isolated detail perspective view of a jacket lift assembly of a mold station;

FIG. 11 is another isolated detail perspective view of a jacket lift assembly of a mold station;

FIG. 12 is another isolated detail perspective view of a jacket lift assembly of a mold station;

FIG. 13 is another isolated detail perspective view of a jacket lift assembly of a mold station;

FIG. 14 is an isolated perspective view of a transfer station;

FIG. 15 is another isolated perspective view of the transfer station;

FIG. 16 is another isolated perspective view of the transfer station;

FIG. 17 is another isolated perspective view of the transfer station;

FIG. 18 is an isolated side sectional view of an index actuator system;

FIG. 19 is another isolated side sectional view of the index actuator system;

FIG. 20 is another isolated side sectional view of the index actuator system;

FIG. 21 is another isolated side sectional view of the index actuator system;

FIG. 22 is a detail end view of the index actuator and portion of a mold car;

FIG. 23 is a detail perspective view of a portion of the manufacturing line including sublines;

FIG. 24 is another detail perspective view of a portion of the manufacturing line including sublines;

FIG. 25 is another detail perspective view of a portion of the manufacturing line including sublines;

FIG. 26 is another detail perspective view of a portion of the manufacturing line including sublines;

FIG. 27 is a detail perspective view of another transfer station and sublines;

FIG. 28 is another detail perspective view of the transfer station and sublines;

FIG. 29 is another detail perspective view of the transfer station and sublines;

FIG. 30 is another detail perspective view of the transfer station and sublines;

FIG. 31 is a detail perspective view of a sand push off station;

FIG. 32 is another detail perspective view of the sand push off station;

FIG. 33 is another detail perspective view of the sand push off station;

FIG. 34 is another detail perspective view of the sand push off station;

FIG. 35 is another detail perspective view of the sand push off station; and

FIG. 36 is another detail perspective view of the sand push off station.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiments of the mold handling system, and such exemplification is not to be construed as limiting the scope of the mold handling system in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described devices, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical devices, systems, and methods. Those of ordinary skill may recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. Because such elements and operations are well known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

An illustrative embodiment of the present disclosure dispenses with hydraulic actuators to move the mold cars on the manufacturing line. Instead, a servo actuator is employed that can accelerate and decelerate slower than a hydraulic actuator. Employing the servo actuator provides more precise movement to create more gradual acceleration and deceleration thereby reducing sudden starts and stops.

In a further illustrative embodiment, for use as part of a transfer station, a servo motor may be coupled to a ballscrew, pulley system, or the like, to more gradually accelerate and decelerate while moving the mold car between sublines. A transfer cart can be affixed to a thrust tube that is linearly movable as a result of the ballscrew rotation. As the servo motor rotates, it rotates the ballscrew, which linearly moves the thrust tube. In this design, a ball nut that is attached to the thrust tube includes one or more concentric threads of ball bearings that ride along corresponding threads of the screw shaft. As the screw shaft rotates, it moves the ball nut and, thus, the thrust tube linearly back and forth. With a cart attached to the thrust tube, when the servo motor rotates, thereby rotating the ballscrew, there is better ability for a more gradual acceleration and deceleration while moving the cart from one subline to the next unlike the sudden starts and stops of hydraulic actuators.

In another embodiment, the thrust tube may be attached to a pivoting dog that can be used to remove the mold car from the transfer cart and placed onto the subline. The servo motor creates a more gradual acceleration and deceleration on the thrust tube, thereby creating a more gentle movement when pulling the mold car off the cart. In contrast, a hydraulic actuator will immediately pull the mold car from the cart, thereby risking damage because of the jerky movement created. Because this mold car pushes against an adjacent mold car to index same, doing so more gently reduces risk of the mold and/or cast part being damaged while indexing segment after segment. In a further embodiment, a pulley system may be attached to the servo motor to move a cart between sublines.

Additional features and advantages of the mold handling line will become apparent to those skilled in the art upon consideration of the following detailed descriptions of carrying out the mold handling line as presently perceived.

A downward looking schematic view of a mold or cast part manufacturing line 2 is shown in FIG. 1. Manufacturing line 2 is composed of four illustrative sublines 4, 6, 8, and 10, respectively. Sublines 4-10 may extend generally parallel to each other. It is appreciated that manufacturing line 2 may be composed of more or less sublines than demonstrated herein. Manufacturing line 2 is capable of manufacturing cast molded parts like valves, couplings, etc., that are formed of a molten metal in the shape as formed in a sand mold. The molten metal is then allowed to cool and solidify forming the part before being removed from manufacturing line 2.

In the illustrative embodiment, a part's mold (see FIGS. 2-7) is made at mold station 12 (see FIGS. 10-13) where it is placed on a mold car 16 located on one of the plurality of segments 14, that form each of sublines 4-10. Here, when a part mold is made, it is placed on a segment 14 on subline 10. One segment 14 represents the space each mold car 16 occupies on each of the sublines. Each X box shown in FIG. 1 represents a single mold car 16 on a segment 14 of each of the sublines and is configured to travel along manufacturing line 2. The plurality of mold cars 16, more than 100, for example, move along sublines 4, 6, 8, and 10 to manufacture the cast parts. It is appreciated that mold cars 16 are positioned adjacent to each other because they push each other along the sublines from one end to the other.

Each mold car 16 is also sized to receive a mold and a jacket that surrounds the mold. Once the mold is formed (see FIGS. 2-7) and a jacket surrounds the perimeter of the mold on mold car 16 (see FIGS. 10-13), it moves in direction 18, along subline 10, until it reaches a transfer station 22. Here, mold car 16 is set onto a transfer cart 24 that moves mold car 16 in direction 26. In order to transfer mold car 16 onto subline 4, mold car 16 is pulled off of transfer cart 24 in direction 20 and onto subline 4. As shown, there is a full row of mold car 16 abutting each other along subline 4. When mold car 16 is moved or indexed onto subline 4, mold car 16 pushes the next abutting mold car in direction 20, indexing it one segment 14 along subline 4. This creates a chain reaction so that each successive abutting mold car 16 likewise indexes along subline 4 in direction 20. As this happens, a mold car 16, at the end of subline 4, is moved onto a transfer cart 32 of transfer station 30, to move same in direction 28 until it reaches subline 6. When this happens, mold car 16 is moved onto subline 6 and in direction 18, pushing or indexing an adjacent mold car 16 in direction 18 as well. All the successive adjacent mold cars are likewise indexed one segment 14 in direction 18 on subline 6.

Illustratively, transfer station 30 may include not only transfer cart 32, but also transfer cart 34. When transfer cart 32 is moved in direction 26 to transfer a mold car 16 from subline 4 to subline 6, illustratively, at the same time, another mold car 16 is concurrently placed onto transfer cart 34 from subline 8 and moved in direction 28. This transfers that mold car 16 from subline 8 to subline 10. It will be appreciated by the skilled artisan upon reading this disclosure how moving or indexing one mold car 16 from segment 14 to another segment 14 creates an orchestrated chain reaction causing all of the other cars to be either moved one segment 14 along one of the sublines 4, 6, 8, and 10, or to be placed onto a transfer cart and moved to a new subline 4, 6, 8, or 10. This is a continuous process to efficiently create cast parts.

Mold car 16 continues to travel in direction 18 along subline 6 as it is being pushed by an adjacent mold car 16 as additional mold cars 16 are being added to and removed from subline 6. In this case, once a mold car 16 is indexed to the end of subline 6, it is placed on transfer cart 38 at transfer station 36. Mold car 16 is then moved from subline 6 in direction 28 to subline 8. Once mold car 16 reaches subline 8, mold car 16 is removed from transfer cart 38 in direction 20 and indexed onto subline 8. Like that described with respect to sublines 4 and 6, successive additions and removals of mold cars 16 onto and off of subline 8 indexes each mold car 16 one segment 14 until that mold car 16 reaches the end of subline 8.

When, at the end of subline 8, mold car 16 is then indexed one more time to move it from subline 8 and onto transfer cart 34 of transfer station 30. At that point, transfer cart 34 moves in direction 28 to transfer mold car 16 from subline 8 to subline 10. And, like the other sublines 4, 6, and 8, mold car 16, on subline 10, is moved in direction 18, pushing an adjacent mold car 16 to index one segment 14. This creates another chain reaction for each successive mold car 16 and, thus, indexing an adjacent mold car in direction 18, along subline 10. It is appreciated that with respect to the transfer stations, after mold car 16 is removed from the transfer cart, the transfer cart returns back to its original position to be available to move the next mold car 16 from one subline to another subline.

A purpose of moving all of these mold cars along successive sublines 4, 6, 8, and 10, is to allow the molten material inside the mold to solidify while remaining undisturbed inside the mold. The end of the process for mold car 16 is when it reaches sand push off station 40 located adjacent mold station 12 (see FIGS. 31-36). At sand push off station 40, the jacket is lifted from mold car 16, the sand and molded part are pushed off of mold car 16. The part is collected and the sand recycled. After that, mold car 16 continues indexing in direction 18 along subline 10 until a new mold and jacket are placed thereon at mold station 12 in order to start the process all over again.

A side view of a mold car 16, with a mold 42 placed thereon, is shown in FIG. 2. This view shows a drag 44 portion of mold 42 placed onto surface 46 of mold car 16. The shape of the molded structure or part pattern 48 is formed in both lower drag 44 portion and upper cope 50 portion of mold 42. In order to accommodate the molten material that needs to fill the part pattern, at least one sprue 52 and runner 54 are formed in cope 50 of mold 42. Sprue 52 provides fluid communication from exterior of cope 50 into runner 54, which is in fluid communication with a part pattern 48. Thus, molten material may be deposited into sprue 52, which will than deposit along runner 54 and into part pattern 48. A parting line 56 defines the border between drag 44 and cope 50. Also shown in this illustrative embodiment are rollers 58 located at the bottom of mold car 16 to allow travel of same along sublines, 4, 6, 8, and 10.

An issue with the mold manufacturing line is its propensity to jostle the mold while on mold car 16 and become damaged. Each drag 44 and cope 50 of mold 42 is made of sand pressed into a shape. This means mold 42 is inherently fragile. With the aforedescribed movement of mold cars 16, between and along sublines 4, 6, 8, and 10, there is opportunity for damage. For example, when a mold car 16 is transferred from one subline to another, a hydraulic actuator (see FIG. 7) typically moves the transfer cart. By nature of the hydraulic actuator, its acceleration and deceleration are almost instantaneous (see FIG. 8). When this happens, drag 44, sitting on surface 46 of mold car 16 might stop slightly faster than cope 50 sitting on top. If this happens, a side shift may be created between drag 44 and cope 50. This side shift is the relative displacement of drag 44 with respect to cope 50, which might damage the image of the part pattern or the molded part itself inside mold 42.

To that end, another side view of a mold car 16, with a mold 42 placed thereon, is shown in FIG. 3. This view differs from mold car 16, with mold 42 sitting on top, shown in FIG. 2, in that mold 42 in FIG. 3 has side shifted. Cope 50 has moved laterally with respect to drag 44 to shift these portions of the mold with respect to each other at parting line 56. This action may distort the part pattern 48 formed within mold 42. If this were to happen prior to depositing the molten material, any resulting part may not form to the correct shape. If this side shift occurs after the material for the part has been poured, the shifting cope 50 might damage the cooling part inside mold 42. In either instance, the result is deleterious. It is also appreciated that damage may occur to mold 42 as a result of mold cars 16 impacting each other by virtue of suddenly starting and stopping the hydraulic actuators. In other words, there are substantial opportunities during the manufacturing process for a cast part to be damaged during its manufacture.

A perspective view of a mold 42 sitting on mold car 16 is shown in FIG. 4. Furthering the image in FIG. 3, mold 42 shows illustrative damage 60 that occurred to cope 50. This is because mold car 16 had been moved via hydraulic actuation. The view in FIG. 5 depicts cope 50 partially separated from drag 44. Sprue 52 is shown extending into part pattern 48 formed in drag 44. Because of the sudden starting and stopping of hydraulic actuation, portions of part pattern 48 are damaged as indicated by reference number 62.

An enlarged view of a portion of drag 44 and cope 50, from FIG. 5, is shown in FIG. 6. Here, damage 62 to part pattern 48 further demonstrates how it can be easily damaged within mold 42.

A side view of a portion of a transfer station on a manufacturing line is shown in prior art FIG. 7. Here, hydraulic actuator 64, with piston arm 66 and coupling 68 attached to transfer cart 32, moves same in directions 28 and 26 between sublines (see, e.g., FIG. 1). At the end of path travel are stops 74 to ensure transfer cart 32 stops in the proper position with respect to the subline. Between the nature of hydraulic actuator 64 and stops 74, there exists a persistent risk of damage as a result of sudden starts and stops. As shown, mold 42, after moving in direction 70 and being stopped by stops 74, may cause cope 50 to move with respect to drag 44 along parting line 56 (resulting in damage similar to that shown in FIGS. 3-6).

To illustrate a difference between hydraulic and servo driven actuators, charts 72 and 73 in FIG. 8 depict relative hypothetical changes in velocity 71 over position 75 between a hydraulic driven actuator and a servo driven actuator. The hydraulic driven actuator, as shown in chart 72, accelerates almost immediately as indicated by line 76 from no velocity to a high velocity, the tube or rod on the actuator travels a constant rate as indicated by line 77, and then decelerates almost immediately as indicated by line 78. By contrast, the servo driven actuator chart 73 demonstrates a gradual acceleration as indicated by line 79. This gradual acceleration is followed by the tube or rod traveling at constant rate 80 and then gradual deceleration 81. It is noted that the lines and units on the charts 72 and 73 are illustrative only to demonstrate a comparison between the operation of a hydraulic driven actuator and a servo driven actuator. The lines do not represent actual side-by-side tested actuators. Nonetheless, it is the gradual increase and decrease in speed, as opposed to sudden increases and decreases in speed that reduces the risk of drag 44 and cope 50 shifting with respect to each other while being moved on manufacturing line 2.

Another downward looking schematic view of cast part manufacturing line 2 is shown in FIG. 9. Manufacturing line 2, like that shown in FIG. 1, is composed of sublines 4, 6, 8, and 10. Also shown are mold station 12, transfer stations 22, 30, 36, and push off station 40. A jacket lift assembly 104 is employed at mold station 12 to place mold jackets 124 onto molds 42 (see FIGS. 10 through 13). With respect to transfer station 22, transfer cart 24 moves a mold car 16, via a servo belt driven line 88, between sublines 10 and 4. At the beginning of each subline 4, 6, 8, and 10, an index actuator 94 is positioned adjacent to each transfer station to pull a mold car 16 from the transfer cart and onto the subline.

Transfer station 30 includes a transfer actuator 96 that moves two transfer carts 32 and 34, respectively, between subline 4 and subline 6 and between subline 8 and subline 10, respectively. Again, index actuators 94 are located adjacent transfer station 30 to pull mold car 16 onto each of sublines 6 and 10, respectively. With respect to transfer station 36, it includes a transfer actuator 98. Like transfer actuator 96, transfer actuator 98 moves a transfer cart 38 between sublines 6 and 8. Another index actuator 94, associated with the subline 8 and located adjacent transfer station 36, is configured to pull mold car 16 from transfer cart 38 and onto subline 8. Push off station 40 includes a push off actuator 200 and another jacket lift actuator 202 (not shown in this view, see FIGS. 31-36).

Isolated detail perspective views of a jacket lift assembly 104 of mold station 12 is shown in FIGS. 10, 11, 12, and 13. These views depict the process of placing mold 42 onto mold car 16 on subline 10. The view in FIG. 10 shows mold station 12 that includes a lifter frame 106 supporting jacket lift assembly 104, which is vertically movable in directions 110 and 112. Jacket lift assembly 104 includes frame 114 that is attached to jacket lift arms 116. An electrically driven servo actuator 118 having an extendable rod 120, movable in directions 110 and 112, is attached to a base 122 of lifter frame 106. Rod 120 is attached to frame 114 in order to move same in either directions 110 or 112. Because frame 114 is attached to jacket lift arms 116, as servo actuator 118 moves rod 120 in direction 110, jacket lift arms 116 are moved upward in direction 110 with respect to subline 10. This is the position of jacket lift arms 116 shown in FIG. 10. Conversely, and as shown in the view of FIG. 12, when servo actuator 118 retracts rod 120 to move frame 114 in direction 112 to lower jacket, lift arms 116 move towards subline 10. The view in FIG. 10 shows formed mold 42 ready to be transferred onto mold car 16. This means lift arms 116, which hold a jacket 124 that fits over mold 42 in order to protect same while traveling along manufacturing line 2, is suspended above mold car 16.

The isolated detail perspective view of jacket lift assembly 104 shown in FIG. 11 includes servo actuator 118 maintaining rod 120 in an extended position to keep frame 114 raised over mold car 16. Mold 42 is moved in direction 26 and onto mold car 16. Once that occurs, as shown in FIG. 12, servo actuator 118 retracts rod 120 in direction 112 lowering jacket lift arms 116, which lowers jacket 124 over mold 42 and onto mold car 16. Once jacket 124 is placed onto mold car 16, it can be indexed one segment to begin its travel through manufacturing line 2.

Fingers 130 extend from jacket lift arms 116 that hold jacket 124 while being lifted, but allows jacket 124 to be removed from jacket lift arms 116 when moved in direction 18 along subline 10. As shown in FIG. 13, mold car 16, with jacket 124 sitting over mold 42, has been indexed one segment 14 (see FIGS. 1 and 9) in direction 18 from its original position as shown in FIGS. 10, 11, and 12. When this happens, the next mold car 16 shown in FIGS. 10, 11, and 12 is also indexed in direction 18 to be in position to receive a new mold 42.

As further shown in FIG. 13, servo actuator 118 extends rod 120 again. When mold car 16 was indexed to the position shown here, jacket 124 engages fingers 130 of jacket lift arms 116, which holds jacket 124 to the extent that it can be lifted in direction 110 by servo actuator 118, as shown. This allows the mold process to start again for this mold car 16 and as shown in FIG. 10. It is appreciated that this process repeats for every mold car 16 that is indexed one segment 14 to the position shown in FIGS. 10-12. As also shown in FIG. 13, another mold car 16 is waiting to receive another mold via this process.

The next step in the process of forming a cast part is transferring mold car 16 described in FIGS. 10-13 to new subline 4. On subline 4 is where the actual part will be cast. However, transferring mold car 16, with mold 42 thereon, poses a risk to same in that it can be damaged. This is because mold car 16 is not only indexed one segment 14 after one segment 14, but it is placed on transfer cart 24 at transfer station 22, which then moves transfer cart 24 to subline 4. This start and stop, as previously described with respect to FIGS. 2-8, is the type of event that can damage mold 42.

The process of transferring mold car 16, with mold 42 and jacket 124 positioned thereon, is shown in the progression views of FIGS. 14, 15, 16, and 17. It is noted that in order to transfer mold car 16 from subline 10 to subline 4, mold car 16 needs to travel across the widths of sublines 6 and 8. For transfer station 22, servo belt driven line 88 provides a relatively gradual start and stop experience for mold car 16. Servo motor 132 is illustratively centrally located and rotates drive pulleys 134, 136, 138, and 140, via belt 142. Illustratively, when servo motor 132 rotates, it causes belt 142, which is positioned on pulleys 134, 136, 138, and 140, to move transfer cart 24 in either directions 26 or 28. Pulleys 138 and 140 span the length of travel in directions 26 and 28 that transfer cart 24 moves. For example, when servo motor 132 rotates in a first direction, it likewise moves belt 142 in direction 26 so that transfer cart 24 moves from subline 10, as shown in FIG. 14, to subline 4, as shown in FIG. 16. Conversely, when mold car 16 is positioned adjacent subline 4, rotating servo motor 132 in the opposite direction moves belt 142 in the opposite direction 28 to return transfer cart 24 back adjacent subline 10. Also shown in these views are illustrative rails 148 along which transfer cart 24 travels between sublines 4 and 10.

The perspective view of transfer station 22 shown in FIG. 15, likewise, includes transfer cart 24 positioned on rails 148 and servo belt driven line 88 located thereunder. This view differs from that shown in FIG. 14 in that mold car 16 has been indexed one segment putting it on transfer cart 24. It is appreciated that, and as discussed previously, mold cars 16 are indexed one segment 14 by virtue of an adjacent mold car 16 pushing another adjacent mold car 16 a distance of one segment 14. This is typically caused by a mold car being pulled from a transfer cart and added to a subline. In case of FIG. 15, when a mold car 16 is pulled onto subline 10 from transfer station 30, every mold car 16 located on subline 10 is indexed one segment 14. When the last mold car 16 is at the end of subline 10, the next time it is moved one segment by the loading of another mold car 16 from transfer station 30, it will be positioned onto transfer cart 24, as shown in FIG. 15.

With mold car 16 positioned on transfer cart 24, being attached to belt 142 means that when servo motor 132 rotates, it moves belt 142 on pulleys 134, 136, 138, and 140 in direction 26, thereby moving mold car 16 toward subline 4. Because the speed of the motor and, thus, the speed of the belt accelerates and decelerates gradually, this transfer of mold car 16 between sublines 10 and 4, shown between FIGS. 14 and 16, does not produce the same sudden start and stop (see comparative hydraulic driven actuator chart 72 and servo driven actuator chart 73 of FIG. 8) as the hydraulic actuator. This reduces the risk of damage to the mold such as that shown in FIGS. 2 and 6. Once mold car 16 is removed from transfer cart 24, servo motor 132 can rotate in an opposite direction, thereby moving belt 142 in the opposite direction 28, returning transfer cart 24 to its starting position adjacent subline 10.

With transfer cart 24 moved to subline 4, mold car 16 is pulled in direction 26 from transfer cart 24, via an index actuator 94 (see, also, FIGS. 18-22). When index actuator 94 pulls mold car 16 onto subline 4, mold car 16 will push an adjacent mold car (not shown in this view) one segment 14. This causes a chain reaction where each successive mold car 16 is likewise pushing and being pushed (i.e., indexed) one segment 14. When mold car 16 is continually indexed until it reaches the end of subline 4, mold car 16 will then be moved onto transfer station 30 (see FIGS. 23-26).

The continuous indexing of mold car 16 one segment at a time is primarily caused by an index actuator pulling mold car 16 off a transfer cart onto a subline. Illustratively, index actuator 94 is located at the beginning of each subline 4, 6, 8, and 10, as shown in FIG. 9. It is appreciated that the operation of index actuator 94 on each of the sublines, 4, 6, 8, and 10 is substantively the same.

Each index actuator 94 is illustratively positioned underneath the subline and is extendable out therefrom. A pivoting member or dog is located at about the end of the index actuator. The dog is pivotable in one direction, but not fully in the other so that when the index actuator extends, its end can be moved under the transfer cart. The dog is pivoted out of the way when moved under the transfer cart. Once under the transfer cart, the dog pivots back upright to serve as a hook. When the index actuator is pulled back in the opposite direction, the dog engages the mold car from the transfer cart and pulls it with the index actuator until the mold car is put onto the subline. It is at that point, as previously identified, that the mold car pushes an adjacent mold car by one segment, which pushes another adjacent mold car by one segment and so on along the subline.

Isolated side sectional views of index actuator 94, along with mold car 16 sitting on transfer cart 24, is shown in the progression views of FIGS. 18, 19, 20, and 21. It is appreciated that this arrangement may be used for any of the sublines 2, 4, 6, and 10. Accordingly, transfer cart 24 shown in these progression views, is illustrative. It is further appreciated that the other transfer carts from the other transfer stations may be employed the same way in these views as transfer cart 24.

The isolated side sectional view in FIG. 18 shows index actuator 94, which includes a servo actuator 150 that moves rod 152 like that previously discussed with respect to servo actuators in this disclosure. A securement bracket 154 couples rod 152 to indexing block 156. Dog 158 is pivotable about pivot pin 160 in directions 162 and 164. It is appreciated that dog 158 is spring-loaded so that it will bias in direction 164. It is further appreciated that a stop (not shown) can be associated with dog 158 so that it will stop moving in direction 164 once it reaches a generally upright position as that shown in FIG. 18. When a transfer cart, such as transfer cart 24, reaches a new subline, such as subline 4, while carrying a mold car 16, servo actuator 150 positions rod 152 in a retracted position. With transfer cart 24 carrying mold car 16 in front of subline 4, mold car 16 is now in position to be pulled onto subline 4 by index actuator 94.

As shown in the isolated side sectional view of FIG. 19, servo actuator 150 extends rod 152, which moves indexing block 156 in direction 18, which pushes dog 158 against the bias force in direction 162 when it hits illustrative bottom corner 166 of front panel 170 of mold car 16. It is appreciated that dog 158 can be configured to hit any portion of mold car 16. Further, transfer cart 24, as well as the other transfer carts may include a slot or cavity, such as cavity 168, to receive a portion of indexing block 156. By servo actuator 150 continuing to extend rod 152 in direction 20, dog 158 is pushed further underneath mold car 16.

In the isolated side sectional view shown in FIG. 20, servo actuator 150 has extended rod 152 so that indexing block 156 moves underneath sufficient for dog 158 to clear corner 166 of panel 170. When this happens, the spring bias that is applied back onto dog 158 in direction 164 (see FIG. 18), causes dog 158 to pivot in direction 164. Servo actuator 150 can then pull rod 152 back in direction 20 causing dog 158 to engage front panel 170 for purposes of pulling mold car 16 in direction 20 as well.

As shown in the isolated side sectional view of FIG. 21, servo actuator 150 continues to move rod 152 in direction 20 pulling indexing block 156 that is pulling on mold car 16, via dog 158, to remove mold car 16 from transfer cart 24. Although not shown in this view, as this happens, mold car 16 engages an adjacent mold car 16 on the subline, indexing it one segment. It is also appreciated that by servo actuator 150 extending rod 152 back in direction 18, as shown in FIG. 19, dog 158 will be pivoted on pivot pin 160 out of the way as mold car 16 continues moving in direction 18 and resetting position to engage in another mold car 16 that is brought over on transfer cart 24.

A detail end view of index actuator 94, and at least a portion of mold car 16, are shown in FIG. 22. In this view, servo actuator 150 is positioned underneath subline 4. Illustrative tracks 172 may be positioned on each side of rail walls 174. Indexing block 156 may include roller bearings 176 or other like bearing structure to allow indexing block 156 to move in directions 18 and 20. A portion of dog 158 is positioned behind front panel 170 (see dashed lines of dog 158) in order to allow mold car 16 to be pulled in direction 20 off transfer cart 24. Rollers 178 may be coupled to mold car 16 to assist in allowing same to move onto rail walls 174. It is appreciated that this same arrangement may be used with all of sublines 4, 6, 8, and 10.

Mold car 16 will continue indexing along subline 4 until it reaches the end. It is appreciated that the casting material may be poured into mold 42 while on subline 4. The remainder of travel of mold car 16 along sublines 4, 6, 8, and 10 allows the casting material to cool until it is removed and the mold and the sand recycled at sand push off station 40 (see FIGS. 31-36).

A detail perspective view of a portion of manufacturing line 2, including sublines 4, 6, 8, and 10, are shown in FIG. 23. In this view, mold car 16 has been indexed to the end of subline 4 and is in position to be transferred to another subline. Similar views of manufacturing line 2 are shown in FIGS. 24, 25, and 26, as well. These are all progression views depicting how mold cars 16 can be transferred from subline 4 to subline 6, as well as from subline 8 to subline 10, respectively. Transfer station 30 is configured to move two mold cars at a single time from one subline to another.

As shown in FIG. 23, mold car 16 on subline 4 is ready to be indexed onto transfer cart 32. Similarly, a mold car 16 is positioned to be indexed onto transfer cart 34. Indexing mold car 16 from sublines 4 and 8 onto transfer carts 32 and 34, respectively, occurs at the same time. Once this is done, transfer actuator 96 moves transfer carts 32 and 34 in direction 28 to transfer mold cars 16 to sublines 6 and 10, respectively. It is appreciated that transfer carts 32 and 34 are connected together via connector 179 so they will both move at one time. Transfer actuator 96 includes a servo actuator 180 that moves rod 182 in either directions 26 or 28 like that previously discussed with respect to other servo actuators. Rod 182 is attached to transfer cart 32, so that as it is moved in directions 26 and 28 so does transfer cart 34. A consequence of this arrangements is that both transfer carts 32 and 34 move at the same time. This allows a single servo actuator to move two mold cars between two separate mold lines. It is appreciated that because of the more gradual acceleration and deceleration of servo actuator 180, in contrast to a hydraulic actuator, there is a reduced risk of damage occurring to mold 42 during this transfer process.

The view in FIG. 24 shows each mold car 16 indexed one segment in direction 20 and onto transfer carts 32 and 34, respectively. As shown in FIG. 25, transfer carts 32 and 34 are moved in direction 28 by servo actuator 180 retracting rod 182, as described illustratively in acceleration line 79 of servo driven actuator chart 73 of FIG. 8, in order to provide a more gradual transfer process. Mold car 16 is then able to be pulled onto its respective sublines 6 and 10, via index actuator 94, as described in FIGS. 18-21.

As identified with respect to FIG. 9, index actuators 94 are employed at the start of sublines 6 and 10, respectively. Pulling mold car 16 onto sublines 6 and 10, respectively, frees transfer carts 32 and 34, so that servo actuator 180 of transfer actuator 96 can move rod 182 in direction 26 in order to return mold carts 32 and 34 to their original position and await new mold cars to be placed thereon for transfer.

Mold car 16 is indexed down subline 6 one segment at a time. This allows the molten material within mold 42 to cool and solidify during this time. At the end of subline 6, mold car 16 needs to transfer to subline 8 (see, also, FIG. 9). Transfer station 36, with transfer cart 38 and transfer actuator 98, will move mold car 16 from subline 6 to subline 8.

In the detail perspective view of FIG. 27, mold car 16 is located at the end of subline 6 and ready to be indexed onto transfer cart 38. The process of moving mold car 16 from subline 6 to subline 8 is shown in the detail perspective progression views of FIGS. 27, 28, 29, and 30. The detail perspective view of FIG. 28, for example, shows mold car 16 being indexed one segment 14 in direction 18 and onto transfer cart 38. Once this is done, mold car 16 is moved in direction 28 along tracks 188 to subline 8. Servo actuator 190 retracts rod 192 (see, also, FIGS. 29 and 30) to pull transfer cart 38 to subline 8. Again, transfer actuator 98 operates the same way as that previously described, and following the acceleration line 79 of servo driven actuator chart 73 of FIG. 8 in order to provide a smoother transfer of mold car 16 between sublines 6 and 8. Therefore, despite being moved between sublines, the risk of damage to mold 42 is reduced without the sudden start and stop of a hydraulic actuator (see, also, FIG. 7).

Mold car 16 can then be indexed, or pulled, onto subline 8 via another index actuator 94 using the process previously described in FIGS. 18-21 (see, also, FIG. 9). Servo actuator 190 of transfer actuator 96 can then extend rod 192 in order to move transfer cart 38 back in direction 26 returning it to subline 6 to await another mold car. It is further appreciated that mold car 16, now on subline 8, will be indexed one segment at a time along subline 8 allowing the molten material within mold 42 to cool during this process. Once mold car 16 reaches the end of subline 8, as shown previously in FIG. 23, it can be indexed onto transfer cart 34, as shown in FIG. 24 and moved to subline 10 as described in the progression views of FIGS. 23, 24, 25, and 26. After index actuator 94 has pulled mold car 16 onto subline 10 (see, also, FIG. 9), the molten material continues to solidify within mold 42.

As shown in FIG. 9, the end of the line for mold car 16 is at sand push off station 40, as shown in detail in FIGS. 31, 32, 33, 34, 35, and 36. In these views, jacket 124 is removed from mold 42 and it along with the cast part are pushed off onto a shakeout conveyor 234. The part is then separated from the sand which is recycled into another mold. Jacket 124 is then placed back onto mold car 16 and indexed along subline 10 to prepare for a new mold 42 to be positioned thereon as previously shown in FIGS. 10 through 13, starting the process over again.

The view in FIG. 31 shows sand push off station 40 with a jacket lift assembly 204 that includes a jacket lift actuator assembly 208 that holds jacket lift actuator 202, which raises and lowers attached jacket lift arms 116 via frame 214. Lift frame assembly 204 includes a rolling lifter frame 206 that is attached to a rolling bracket 220 located on each side of lower lifter frame 206. Rollers 222 on rolling brackets 220, respectively, move along rails 223 allowing lower lifter frame 206 to be movable in directions 28 and 26. A push off actuator 200, which includes a servo actuator 224 and rod 226, selectively extend and retract lower lifter frame 206 in directions 28 and 26. This movement is to allow push panel 228 to move over mold car 16 to push mold 42 off of same, as shown in the further progression views.

As shown in FIG. 32, jacket 124 on mold car 16 fits between jacket lift arms 116. When in this position, and as shown in FIG. 33, servo actuator 230 of jacket lift actuator 202 extends rod 232 like that described herein with respect to such servo actuators to lift frame 214 in direction 110 to raise jacket 124 off of mold 42 from mold car 16.

With mold 42 now exposed, servo actuator 224 of push off servo actuator 200, extends rod 226 in direction 28, as shown in FIG. 34. This moves roller lifter frame 206 in direction 28 via rollers 222 rolling along rails 223. Push panel 228 thereby moves over mold car 16 pushing mold 42 off of same and into shakeout conveyor 234 in order for the part to be removed and the sand recycled. With mold 42 removed, push off servo actuator 200 further extends lower lifter frame 206 in direction 28 with jacket 124 still being held by jacket lift arms 116. Jacket lift actuator 202 retracts rod 232, thereby lowering frame 214 in direction 112 so that jacket 124 fits over jacket brush 236 as shown in FIG. 35. It is appreciated that jacket brush 236 cleans the interior of jacket 124 in anticipation of receiving a new mold.

The view shown in FIG. 36 depicts roller lifter frame 206 being retracted by push off servo actuator 200 pulling rod 226 in direction 26 returning lower lifter frame 206 back to its original position. This also returns jacket 124 over mold car 16 where it can then proceed in direction 18 by being indexed one segment to repeat the process at mold station 12 as shown in FIG. 10.

In the drawings, some structural or method features may be shown in specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, may not be included or may be combined with other features. It should also be appreciated that, to the extent any subject matter disclosed in this non-provisional patent document conflicts with the priority application, the disclosure from this non-provisional patent document controls.

Claims

1. A mold handling manufacturing line that moves at least one mold car that supports a cast mold which forms a cast part, the mold handling manufacturing line comprising:

a first subline;

a second subline located substantially parallel with and spaced apart from the first subline;

a third subline located substantially parallel with and spaced apart from the first subline and the second subline;

a fourth subline located substantially parallel with and spaced apart from the first subline, the second subline, and the third subline;

a first transfer station in communication with the fourth subline and the first subline; wherein the first transfer station includes a transfer cart configured to receive the at least one mold car; wherein the first transfer station includes a servo belt driven line composed of a servo motor that is about centrally located with respect to the first transfer station and rotates one or more drive pulleys via a belt; wherein the belt is coupled to the transfer cart; wherein, when the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the fourth subline and the first subline; wherein, when the servo motor rotates in a second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a second linear direction between the fourth subline and the first subline; and

a second transfer station located distal from the first transfer station; wherein the second transfer station is in communication with the first subline, the second subline, the third subline; and the fourth subline; wherein the second transfer station includes a first transfer cart configured to receive the at least one mold car and a second transfer cart configured to receive another at least one mold car; wherein a servo actuator, as part of the second transfer station, moves a rod in the first linear direction and the second linear direction; and wherein the rod is attached to the first transfer cart of the second transfer station and the second transfer cart of the second transfer station, so that the first transfer cart of the second transfer station and the second transfer cart of the second transfer station are movable in the first linear direction and the second linear direction together as the rod correspondingly moves in the first linear direction and the second linear direction to move the first transfer cart of the second transfer station between the first subline and the second subline and the second transfer cart of the second transfer station between the third subline and the fourth subline.

2. The mold handling manufacturing line of claim 1, wherein the one or more drive pulleys of the first transfer station includes a first pulley and a second pulley wherein the first pulley is spaced apart from the second pulley and spans a distance that is at least a length of travel of the first transfer cart.

3. The mold handling manufacturing line of claim 1, wherein when the servo motor rotates in the first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in the first linear direction to the fourth subline, when the servo motor rotates in the second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in the second linear direction to the first subline.

4. The mold handling manufacturing line of claim 1, further comprising an index actuator that operates adjacent the first transfer station and the first subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein when the transfer cart of the first transfer station is located adjacent the first subline the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the first transfer station onto the first subline.

5. The mold handling manufacturing line of claim 1, further comprising an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline.

6. The mold handling manufacturing line of claim 1, further comprising an index actuator that operates adjacent the second transfer station and the fourth subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the second transfer cart of the second transfer station is located adjacent the fourth subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the another at least one mold car in order to pull the another at least one mold car from the transfer cart of the second transfer station onto the fourth subline.

7. The mold handling manufacturing line of claim 1, wherein the servo actuator of the second transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the first transfer cart of the second transfer station and the second transfer cart of the second transfer station attached.

8. The mold handling manufacturing line of claim 6, wherein the servo actuator of the index actuator rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the indexing block attached.

9. The mold handling manufacturing line of claim 6, further comprising a third transfer station located distal from the second transfer station, wherein the third transfer station is in communication with the second subline and the third subline, wherein the third transfer station includes a transfer cart configured to receive the at least one mold car, wherein a servo actuator, as part of the third transfer station, moves a rod in the first linear direction and the second linear direction, and wherein the rod is attached to the transfer cart of the third transfer station so that the transfer cart of the third transfer station is movable in the first linear direction and the second linear direction as the rod correspondingly moves in the first linear direction and the second linear direction to move the transfer cart of the third transfer station between the second subline and the third subline.

10. The mold handling manufacturing line of claim 9, wherein the servo actuator of the third transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the third transfer station attached.

11. The mold handling manufacturing line of claim 1, further comprising a jacket lift assembly configured to place a mold jacket over a mold on the at least one mold car, wherein the jacket lift assembly includes one or more jacket lift arms, wherein a servo actuator includes an extendable rod that is attached to a frame, which is attached to the one or more jacket lift arms to extend or retract the one or more jacket lift arms.

12. The mold handling manufacturing line of claim 11, wherein the servo actuator of the jacket lift assembly rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the frame of the jacket lift assembly attached.

13. The mold handling manufacturing line of claim 1, further comprising a sand push off station configured to remove the cast mold made of sand from the at least one mold car, wherein the sand push off station includes a jacket lift actuator assembly and a push off actuator assembly, wherein the jacket lift actuator assembly includes a jacket lift servo actuator that is configured to selectively raise and lower one or more jacket lift arms, via a frame, to remove a jacket prior to removing the sand from the cast mold on the at least one mold car, and wherein the push off actuator assembly includes a push off servo actuator that has an extendable rod which moves the jacket lift actuator assembly so that after the jacket lift actuator assembly lifts the jacket from a mold, the push off servo actuator is configured to move the jacket lift actuator assembly and the mold seated on the at least one mold car.

14. The mold handling manufacturing line of claim 13, wherein the push off servo actuator of the push off actuator assembly rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the frame of the push off actuator assembly attached.

15. A mold handling manufacturing line that moves at least one mold car that supports a cast mold, which forms a cast part, the mold handling manufacturing line comprising:

at least a first subline and a second subline;

wherein the second subline is located substantially parallel with and spaced apart from the first subline;

a first transfer station in communication with the first subline and the second subline; wherein the first transfer station includes a transfer cart configured to receive the at least one mold car; wherein the first transfer station includes a servo belt driven line composed of a servo motor that is about centrally located with respect to the first transfer station and rotates one or more drive pulleys via a belt; wherein the belt is coupled to the transfer cart; wherein when the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the first subline and the second subline; and wherein when the servo motor rotates in a second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a second linear direction between the first subline and the second subline.

16. The mold handling manufacturing line of claim 15, wherein the servo motor of the first transfer station rotates a ballscrew, which linearly moves a rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the first transfer station attached.

17. The mold handling manufacturing line of claim 15, further comprising an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline.

18. A mold handling manufacturing line that moves at least one mold car that supports a cast mold, which forms a cast part, the mold handling manufacturing line comprising:

At least a first subline and a second subline;

wherein the second subline is located substantially parallel with and spaced apart from the first subline;

a first transfer station in communication with the first subline and the second subline; and

wherein the first transfer station includes a transfer cart configured to receive the at least one mold car, wherein a servo actuator as part of the third transfer station moves a rod in a first linear direction and a second linear direction, and wherein the rod is attached to the transfer cart of the first transfer station so that the transfer cart of the first transfer station is movable in the first linear direction and the second linear direction as the rod correspondingly moves in the first linear direction and the second linear direction to move the transfer cart of the first transfer station between the first subline and the second subline.

19. The mold handling manufacturing line of claim 18, wherein the servo actuator of the first transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the first transfer station attached.

20. The mold handling manufacturing line of claim 18, further comprising an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline.