AXIAL PUMP AND RISER

Abstract

A device for pumping molten metal includes a pump configured to pump molten metal, wherein the pump comprises (i) a motor, (ii) a shaft having a first end connected to the motor, and a second end connected to a rotor, wherein the rotor is configured to push molten metal upwards as it rotates. At least part of the shaft and the rotor are positioned in a conduit of a riser. The riser has an outer surface, a front, a bottom, a two-stage conduit, an inlet and an outlet above the inlet and below the motor. The two-stage conduit has a lower stage and a an upper stage, wherein the lower stage is generally cylindrical and the upper stage has a circular cross-sectional portion and one or more lobes extending from and in communication with the circular cross-sectional portion.

Claims

1. A device for pumping molten metal, the device comprising: (a) a pump configured for pumping molten metal, wherein the pump comprises (i) a motor, (ii) a shaft having a first end connected to the motor, and a second end connected to a rotor, wherein the rotor is configured to push molten metal upwards; and (b) a riser having an outer surface, a front, a bottom, an inlet, an outlet above the inlet, and a two-stage conduit having an upper stage comprising a first cross-sectional area and a lower stage beneath the upper stage, wherein the lower stage has a second cross-sectional area that is greater than the first cross-sectional area.

2. The device of claim 1, wherein the pump further includes a platform on which the motor is positioned, and the platform is attached to a clamp, and the clamp is further attached to the top of the riser.

3. The device of claim 1, wherein the riser has a bottom portion comprised of graphite and a top portion comprised of ceramic.

4. The device of claim 1 that further includes a transition between the upper stage and the lower stage.

5. The device of claim 4, wherein the transition expands from the first cross-sectional area where it connects to the upper stage to the second cross-sectional area where it connects to the lower stage.

6. The device of claim 4, wherein the transition has a height that is less than a height of the lower stage.

7. The device of claim 4, wherein the transition has a height that is less than a height of the upper stage.

8. The device of claim 1, wherein the upper stage has a clover-shaped cross section.

9. The device of claim 1, wherein the lower stage has a circular cross section.

10. The device of claim 1, wherein the upper stage has a cross-section comprising a circular center and a plurality of lobes extending from and connected to the circular center.

11. The device of claim 10 that has four lobes.

12. The device of claim 1, wherein a distance between the outlet and the inlet is 2 feet or more.

13. The device of claim 1 that further includes a clamp that connects the pump to the riser.

14. The device of claim 13, wherein the clamp includes a plate that rests on a top surface of the riser the first plate and the opening is aligned with the transfer outlet.

15. The device of claim 14, wherein the clamp further includes side portions that connect to a side of the riser.

16. The device of claim 10, wherein each of the plurality of lobes has the same size and shape as the other of the plurality of lobes.

17. The device of claim 1, wherein the upper stage has at least two lobes on opposing sides of a center portion and a width W1 between the lobes, wherein the width W1 is equal to the cross-sectional width of the lower stage of the conduit.

18. The device of claim 1, wherein the lower stage has a first cross-sectional width and the upper stage has circular portion having a second cross-sectional width, wherein the first cross-section width is greater than the second cross-sectional width.

19. The device of claim 1, wherein the upper stage has a height and the lower stage has a height that is less than the height of the upper stage.

20. The device of claim 1, wherein the inlet has a cross-sectional width at a bottom surface of the riser that is greater than a cross-sectional width of the lower stage of the conduit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a side, perspective view of a device according to this disclosure.

[0016] FIG. 2 is a side, perspective, exploded view of the device of FIG. 1.

[0017] FIG. 3 is a top view of the device of FIG. 1.

[0018] FIG. 4 is a front, partial cross-sectional view of the device of FIG. 1.

[0019] FIG. 5 is a side, partial cross-sectional view of the device of FIG. 1.

[0020] FIG. 6 is a rear view of the device of FIG. 1.

[0021] FIG. 7 is a perspective, front view of the device of FIG. 1.

[0022] FIG. 8 is a top view of the device of FIG. 7.

[0023] FIG. 9 is a cross-sectional side view taken along line A-A of FIG. 8.

[0024] FIG. 10 is a front, partial cross-sectional view of the pump base of FIG. 1.

[0025] FIG. 11 is a cross-sectional view taken along line B-B of FIG. 10.

[0026] FIG. 12 is a cross-sectional view taken through line C-C of FIG. 10.

[0027] FIG. 13 is a top view of a riser according to this disclosure.

[0028] FIG. 14 is a side, cross-sectional view taken along line D-D of FIG. 14.

[0029] FIG. 15 is a front, perspective, partial cross-sectional view of the riser of FIGS. 13 and 14.

DETAILED DESCRIPTION

[0030] Turning now to the drawings, where the purpose is to describe a preferred embodiment of the invention and not to limit same, a device 10 generally includes a pump 100 and a riser 500.

Pump

[0031] As seen, for example, in FIGS. 1-10, pump 100 is of any suitable design (and can be a circulation pump or gas-release pump) satisfactory to move molten metal upwards in conduit 300 of in the riser 500 as described herein. The pump 100 preferably has a pump support (or “support” or “weldment”) 122, a drive source 124 (which is most preferably a pneumatic motor) mounted on the support 122, and a drive shaft 128. Motor 124 as shown is secured (at least in part) to support 122 by a strap 125. Motor 124 preferably is partially surrounded by a cooling shroud 131 that circulates air generated by blower 130, which is known in the art.

[0032] Drive shaft 128 preferably includes a motor drive shaft 128A that extends downward from the motor 124, a rotor shaft 128B, and a coupling 128C. Motor drive shaft 128A is preferably comprised of steel. Rotor drive shaft (or rotor shaft) 128B is preferably comprised of graphite, or graphite coated with a ceramic, but can be comprised of any suitable material. Coupling 128C is preferably comprised of steel and connects the motor drive shaft 128A to the first end 128B1 of the rotor drive shaft 128B.

[0033] A rotor 200, best seen in FIG. 2, is positioned in the conduit 300 and is connected to a second end 128B2 of the rotor shaft 128B. Rotor 200 is configured to push molten metal upwards and it may be a two-stage rotor with blades that each include an angled section to push molten metal up into conduit 300.

[0034] The components of pump 100 that are immersed in molten metal, such as the rotor 200 and rotor shaft 128, are preferably comprised of graphite and/or ceramic.

[0035] Pump 100 as shown has no support posts or pump base.

Riser

[0036] Riser 500 is configured to have pump 100 positioned thereon with rotor shaft 128B and rotor 200 positioned at least partially in the conduit 300. Riser 500 as shown is a generally rectangular structure, but can be of any suitable shape or size, wherein the size depends at least in part on the size of the pump with which the riser 500 is used. Outlet 510 is of any suitable size and shape to permit molten metal to pass through it, and is above inlet 506 and below motor 124.

[0037] Riser 500 is preferably comprised of material capable of withstanding the heat and corrosive environment of molten metal (particularly molten aluminum). Most preferably the heat resistant material is a high temperature, castable cement, with a high silicon carbide content, such as ones manufactured by AP Green or Harbison Walker, each of which are part of ANH Refractory, based at 400 Fairway Drive, Moon Township, PA 15108, or Allied Materials, and riser 500 is cast or otherwise formed in any suitable manner. Cement (if used) to connect riser 500 to another structure is of a type known by those skilled in the art.

[0038] The riser 500 may have a bottom portion B and a top portion T. The bottom portion is preferably comprised of or consists of graphite because graphite is relatively inexpensive and simple to machine. The top portion may be comprised of ceramic such as silicon carbide, which is harder than graphite and also more resistant to corrosion. Alternatively, riser 500 may be comprised entirely of graphite or entirely of ceramic.

[0039] Riser 500 as shown has four sides 502A, 502B, 502C and 502D, a bottom 502E a top 502F, an inlet 506, a conduit 300, and an outlet 510.

[0040] Inlet 506 functions to allow molten metal to pass through it and into conduit 300. As shown, inlet 506 is formed in bottom 502E, and riser 500 can be raised from the bottom surface of a vessel into which it is positioned in any suitable manner to allow molten metal to enter inlet 506. For example, riser 500 may be suspended or have gaps formed in one or more sides 502A, 502B, 502C, 502D to permit molten metal to enter inlet 506. Alternatively, riser 500 may have support legs or it may rest on a support in order to position bottom 502E above the bottom surface of a vessel in which device 10 is positioned.

[0041] Alternatively, inlet 506 may be formed in any of sides 502A, 502B, 502C, or 502D, preferably starting about 0″-2″, 2″-6″, or 1.5″-3″, from bottom surface 502E. If formed in a side surface of riser 500, inlet 506 could have a height of about 2″-4″ (or about 3.25″) and a width of about 4″-6″ (or about 5″). If the inlet 506 is in bottom 502E as shown, it may have a cross-sectional area that is 5%-10%, 10%-20%, 20%-30%, 30%-40%, 40%-50%, or any amount from 5%-50% larger (or smaller) than the cross-sectional area of lower stage 302 of conduit 300. The cross-sectional area of inlet 506 is measured at the outer surface on which it is located, such as the outer surface of bottom 502E. Inlet 506 can be of any suitable size and shape, and as shown flares outward from bottom stage 302 of conduit 300 and is about 3% to 10% wider at bottom 502E than the width of lower stage 302. As shown, inlet 506 has a width at bottom 502E that is greater than 50% of the width, or about 75%-85% the width of bottom 502E as measured along side 502A, 502B, 502C, or 502D.

[0042] Insulation 530 is positioned between the pump motor support and the surface 502F of riser 500.

Conduit

[0043] Conduit 300 has two stages, lower stage 302 and upper stage 310, and a transition 350 that connects lower stage 302 and upper stage 310. Lower stage 302 is preferably cylindrical and has a circular cross section (as shown, for example, in FIG. 12), although lower stage 302 could be of any suitable shape. Lower stage 302 has a cross-sectional diameter that as shown is greater than ½ the width of riser 300, and it can be between 30%-70%, or 40%-75%, or 50% or more, or 60% or more of the width of riser 500. Lower stage 302 has a bottom 304 that connects to and communicates with inlet 506 and a top 306 that connects to and communicates with transition 350. As shown, lower stage 302 has a height of about 25%-35% of the height of riser 500 and about 30%-40% of the height of conduit 300, although lower stage 302 could be of any suitable height. Conduit 300's height is measured from bottom 304 to the lower lip 510A of outlet 510.

[0044] Upper stage 310 has a clover-leaf cross-sectional shape (as shown, for example, in FIG. 11). Upper stage 310 includes, in cross section, a circular center 312 and four lobes 314A, 314B, 314C, and 314D, connected to and in communication with circular center 312. The purpose of the lobes is to help prevent a vortex from forming as molten metal is being pumped up through conduit 300.

[0045] Although four lobes are shown, one or more lobes, or a plurality of lobes, may be utilized, as long as they are of sufficient number, size and shape to prevent a vortex from forming under normal pump operating parameters.

[0046] As shown, the cross-sectional area of lower stage 302 is greater than the cross-sectional area of upper stage 310, although any suitable cross-sectional area for lower stage 302 and upper stage 310 may be utilized. The cross-sectional width W1 of upper stage 310 as measured across lobe 314A and lobe 314C is the same as the cross-sectional width of lower stage 302, although W1 could be any suitable width. The cross-sectional width as measured across lobe 314B and lobe 314D is also W1 and is the same as the cross-sectional width of lower stage 302, although the width as measured across lobes 314B and 314D need not be the same as W1 and need not be the same as the cross-sectional width of lower stage 302.

[0047] Each lobe shares a connecting point with an adjacent lobe. Lobe 314A has a connecting point 316 with lobe 314B. Lobe 314B has a connecting point 318 with lobe 314C. Lobe 314C has a connecting point 320 with lobe 314D. Lobe 314D has a connecting point 322 with lobe 314A. As shown, the cross-sectional width from connecting point 316 to connecting point 320 and from connecting point 318 to connecting point 322 are the same, although they need not be the same. Additionally, the cross-sectional width between the connecting points is less than the cross-section width of lower stage 302 and is about 10%, 20%, 30%, 10%-20%, 15%-25%, or 15%-30% less than the cross-sectional width W1, although any suitable width may be used.

Clamp

[0048] Clamp 600 is preferably comprised of steel and has a plate 602 that is configured to be positioned on top surface 502F of riser 500 and be connected thereto by suitable fasteners. Side portions 604 extend downward on side 502A along the sides of opening 510 and are preferably fastened to side 502A. Cross bars 606 help maintain the stability of clamp 600.

Operation

[0049] In operation, when the motor 100 is activated it rotates the rotor shaft 128 and rotor 200. The rotor 200 pumps molten metal upwards through the lower stage 302 of the conduit 300, into the upper stage 310 of the conduit, and out of the outlet 510. The one or more lobes 314A, 314B, 314C, and 314D help to stop a vortex from forming. A vortex can lead to turbulent flow of the molten metal and the formation of dross because the molten metal contacts more air and hence more oxygen. The outlet 510 may be connected to a pipe, launder or other structure that further transfers the molten metal.

[0050] Some non-limiting examples of this disclosure are as follows:

[0051] Example 1: A device for pumping molten metal, the device comprising: [0052] (a) a pump configured for pumping molten metal, wherein the pump comprises (i) a motor, (ii) a shaft having a first end connected to the motor, and a second end connected to a rotor, wherein the rotor is configured to push molten metal upwards; and [0053] (b) a riser having an outer surface, a front, a bottom, an inlet, an outlet above the inlet, and a two-stage conduit having an upper stage comprising a first cross-sectional area and a lower stage beneath the upper stage, wherein the lower stage has a second cross-sectional area that is greater than the first cross-sectional area.

[0054] Example 2: The device of example 1, wherein the pump further includes a platform on which the motor is positioned, and the platform is attached to a clamp, and the clamp is further attached to the top portion of the riser.

[0055] Example 3: The device of example 1, wherein the bottom portion of the riser is comprised of graphite and the top portion of the riser is comprised of ceramic.

[0056] Example 4: The device of example 2, wherein the second cross-sectional area is 25% or more greater than the first cross-sectional area.

[0057] Example 5: The device of example 1 that further includes a transition between the upper stage and the lower stage.

[0058] Example 6: The device of example 6, wherein the transition expands from the first cross-sectional area where it connects to the upper stage to the second cross-sectional area where it connects to the lower stage.

[0059] Example 7: The device of example 6, wherein the transition has a height that is less than a height of the lower stage.

[0060] Example 8: The device of example 6, wherein the transition has a height that is less than a height of the upper stage.

[0061] Example 9: The device of example 1, wherein the upper stage has a clover-shaped cross section.

[0062] Example 10: The device of example 2, wherein the lower stage has a circular cross section.

[0063] Example 11: The device of example 2, wherein the upper stage has a cross-section comprising a circular center and a plurality of lobes extending from and connected to the circular center.

[0064] Example 12: The device of example 11 that has four lobes.

[0065] Example 13: The device of example 11 that has between one and four lobes.

[0066] Example 14: The device of example 1, wherein a distance between the outlet and the inlet is 2 feet or more.

[0067] Example 15: The device of example 3, wherein the clamp has a plate attached to a top surface of the metal transfer conduit and the clamp is also attached to the platform.

[0068] Example 16: The device of example 15, wherein the clamp further includes side arms connected to a side of the riser.

[0069] Example 17: The device of example 15, wherein the clamp further includes a step-up section that connects the first plate to the second plate, wherein the step-up section is connected to a side of the platform.

[0070] Example 18: The device of example 3, wherein the riser has grooves in two sides and the clamp has side plates with ridges that are received in the grooves.

[0071] Example 19: The device of example 11, wherein each of the plurality of lobes has the same size and shape as the other of the plurality of lobes.

[0072] Example 20: The device of example 11, wherein each of the plurality of lobes is formed at a 90° angle to the adjacent each of the other plurality of lobes.

[0073] Example 21: The device of any one of examples 1-21 that includes insulation between the motor support and the top of the riser.

[0074] Example 22: The device of any one of examples 11-13 or 19-20, wherein the center portion of the upper stage of the conduit has a width, and each of the one or more lobes has a width, and the width of the center portion is greater than the width of each of the one or more lobes.

[0075] Example 23: The device of any one of examples 11-13, 19-20, or 22, wherein each of the plurality of lobes is spaced equidistantly about the center portion.

[0076] Example 24: The device of any one of examples 1-23, wherein the lower stage has a cross-sectional width and the circular portion of the upper stage has a cross-sectional width and the cross-sectional width of the lower stage is greater than the cross-sectional width of the circular portion of the upper stage.

[0077] Example 25: The device of example 27, wherein the cross-sectional width of the lower stage is 50%-100% greater than the width of the center portion of the upper stage.

[0078] Example 26: The device of any one of examples 1-25, wherein the inlet is in the bottom surface.

[0079] Example 27: The device of any one of examples 1-11 or 12-27, wherein the upper stage has at least two lobes in either side of the center portion and a distance between measured between the ends of the lobes, wherein the distance is equal to the cross-sectional width of the lower stage of the conduit.

[0080] Having thus described some embodiments of the invention, other variations and embodiments that do not depart from the spirit of the invention will become apparent to those skilled in the art. The scope of the present invention is thus not limited to any particular embodiment, but is instead set forth in the appended claims and the legal equivalents thereof. Unless expressly stated in the written description or claims, the steps of any method recited in the claims may be performed in any order capable of yielding the desired result.