SMART MOLTEN METAL PUMP

Abstract

A smart molten metal pump system and method automatically controls the operating speed of the pump rather than requiring an operator to control the speed. The system includes a pump, a controller for controlling the speed of the pump and one or more vibration sensors (such as an accelerometer) to measure vibration. The controller receives input about the vibration of the pump or one or more pump components, and possibly other data, such as the temperature of the molten metal, and/or the depth of the molten metal, ad/or parameters related to the operation of the pump. The controller analyzes the one or more inputs to vary the speed of the pump, turn the pump off, and/or send a communication to an operator.

Claims

1. A molten metal pump system comprising: (a) a molten metal pump having a plurality of pump structures that include: a rotor shaft, a motor shaft, a motor, a superstructure, a rotor, one or more support posts, and a pump base; (b) a controller for controlling the speed of the pump; (c) a vibration sensor on or in one or more of the plurality of pump structures, wherein the vibration sensor is configured to detect vibration and communicate the vibration to the controller; and (d) a second vibration sensor on or in one of the plurality of pump structures different from the pump structure that includes the vibration sensor, wherein the second vibration sensor is configured to detect vibration and communicate the vibration to the controller. wherein the controller varies the speed of the pump, turns off the pump, and/or sends a message to a monitor or operator, based on the vibration detected by the vibration sensor and/or the vibration detected by the second vibration sensor.

2. The molten metal pump system of claim 1, wherein the controller is programmed with (a) a maximum vibration level for the vibration sensor and the controller is configured to turn off the molten metal pump if the maximum vibration level is exceeded, and (b) a second maximum vibration level for the second vibration sensor and the controller is configured to turn off the molten metal pump if the second maximum vibration level is exceeded.

3. The molten metal pump system of claim 1 that further includes a thermocouple positioned in one or more of: the pump base, one or more of the one or more support posts, the rotor, or the rotor shaft, wherein the thermocouple is configured to measure the temperature of molten metal in which the pump is positioned and communicate the temperature to the controller.

4. The molten metal pump system of claim 1, wherein the controller is remote to the pump.

5. The molten metal pump system of claim 1, wherein the controller is on the superstructure of the pump.

6. The molten metal pump system of claim 3, wherein the thermocouple is in an enclosed box that is configured to be positioned beneath the molten metal when the molten metal pump is positioned in a molten metal bath, so the thermocouple does not contact the molten metal.

7. The molten metal pump system of claim 1 that further includes a laser on the superstructure, wherein there is an insulating material between the superstructure and the laser.

8. The molten metal pump system of claim 1, wherein a second thermocouple is positioned in the vessel, is remote from the pump, and is configured to communicate with the controller.

9. The molten metal pump system of claim 8, wherein the communication from the thermocouple to the controller is wireless.

10. The molten metal pump system of claim 7, wherein the communication from the laser to the controller is wireless.

11. The molten metal pump system of claim 1, wherein the communication from the vibration sensor to the controller is wireless.

12. The molten metal pump system of claim 1, wherein the communication from the second vibration sensor to the controller is wireless.

13. The molten metal pump system of claim 1 that further comprises a display that shows a measured temperature of the molten metal, a measured depth of the molten metal, and speed of the molten metal pump.

14. The molten metal pump system of claim 1, wherein the controller comprises a memory that stores an operational history of the molten metal pump.

15. The molten metal pump system of claim 1, wherein the controller can be accessed from a remote location.

16. The molten metal pump system of claim 15, wherein the controller can be re-programmed from the remote location.

17. The molten metal pump system of claim 1, wherein the vibration sensor is an accelerometer, and the second vibration sensor is an accelerometer.

18. The molten metal pump system of claim 1, wherein there is an insulating material between the superstructure and a molten metal bath when the molten metal pump is in a molten metal bath.

19. The molten metal pump system of claim 13, wherein the controller: varies the speed of the pump, turns off the pump, and/or sends a message to a monitor or operator, based on (a) the temperature of the molten metal, (b) the depth of the molten metal, and/or (c) the vibration of the pump.

20. The molten metal pump system of claim 1, wherein the controller is further configured to receive one or more of the pump speed and pump load and wherein the controller: varies the speed of the pump, turns off the pump, and/or sends a message to a monitor or operator, based on (a) the temperature of the molten metal, (b) the depth of the molten metal measured, (c) the speed of the pump, and/or (d) the pump load.

21. The molten metal pump system of claim 7 that further comprises a second depth-measuring device mounted and configured so as to measure the depth of molten metal in a second vessel, wherein the second depth device is in communication with the controller.

22. The molten metal pump system of claim 1 that further comprises a scale that measures the weight of molten metal in a structure and communicates the weight to the controller.

23. The molten metal pump system of claim 1, wherein the vibration sensor is on or in the rotor shaft and the second vibration sensor is in the rotor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 is a front, perspective view of a pump for pumping molten metal according to this disclosure.

[0022] FIG. 2 is a partial, cross-sectional view of a pump base that may be used with the pump of FIG. 1.

[0023] FIG. 2a is a top, perspective view of a pump base that may be used with the pump of FIG. 1.

[0024] FIG. 3 is a top, perspective view of a rotor according to this disclosure.

[0025] FIG. 4 is a cross-sectional side view of an exemplary system according to this disclosure.

[0026] FIG. 5 is the system of FIG. 4 showing the level of molten metal in the furnace being increased.

[0027] FIG. 6 is a top view of the system of FIG. 4.

[0028] FIG. 7 is a partial, cross-sectional side view of an exemplary system according to this disclosure.

[0029] FIG. 8 is a partial, cross-sectional side view of an exemplary system according to this disclosure.

[0030] FIG. 9 is a front, partial perspective view of an exemplary system according to this disclosure.

[0031] FIG. 10 is schematic representation of an exemplary system according to this disclosure.

[0032] FIG. 11 shows the system of FIG. 10 and represents different levels of molten metal in the vessel.

[0033] FIG. 12 shows the system of FIG. 10 in which the level of molten metal has decreased to a minimum level.

[0034] FIG. 13 shows a controller panel that may be used to control a pump used in a system according to this disclosure.

DETAILED DESCRIPTION

[0035] Turning now to the figures, wherein the purpose is to describe an embodiment of this disclosure and not to limit same, a smart molten metal pump system 10 can include a molten metal circulation pump, gas-injection (or gas-release) pump, or transfer pump. Currently, most molten metal pumps use a variable frequency drive (“VFD”) to control the speed of the pump. An operator controls the pump speed based on observing various operating parameters.

[0036] A smart pump system 10 as disclosed uses a program logic controller (“PLC” or “controller”) 170 and human machine interface (“HMI”) for additional functionality and feedback. It optionally utilizes SCADA (supervisory control and data acquisition) hardware/software with a GE IFIX 75 tag for remote monitoring of the pump 22, such as from an office at an aluminum processing facility.

[0037] A computer 500 for accessing and monitoring data received by the controller 170, and/or controlling the pump 22, may be located at an operator's location, such as at an office at the processing facility. The controller 170 may also be accessible by a hand-held device 510 such as a cellular phone. Further, the controller 170 may also be accessible by a computer 520 at the pump manufacturer's facility. Any suitable wired or wireless connection between a computer 500, hand-held device 510, manufacturer's computer 520, and the controller, such as an Ethernet connection, may be utilized. The pump's operational and input information can also be stored over time for troubleshooting: the pump 22, the vessel in which the pump 22 operates, other vessels, and/or the operational system and method used at the processing facility in which the pump 22 is located.

[0038] The measured inputs (or “inputs”) to the controller 170 are one or more of: (1) the molten metal temperature in one or more vessels (such as the furnace pump well, a launder and/or a ladle); (2) the depth (or level) of the molten metal in one or more of the afore-mentioned vessels, which could be measured in any suitable manner, such as by a laser measuring device or float; (3) the vibration of the pump 22, or of a pump component (such as the drive shaft 42 or rotor 100), by a vibration sensor at any suitable location on the pump; (4) the weight of molten metal in a structure, such as a mold or ladle; and (5) pump speed, pump load, and other information. The controller 170 may also include the date the pump 22 was installed and maintenance history for the pump 22.

[0039] The controller 170 may control the speed of the pump 22, turn the pump 22 on, turn the pump 22 off, and/or send a signal to an operator, based on one or more of the measured inputs. For example, if shaft 42 breaks, a vibration sensor would detect it and turn the pump 22 off. The controller 170 can also be programmed to develop a relationship between two or more of the inputs, e.g., two or more of: temperature of the molten metal, level of the molten metal, vibration, speed of the pump, and pump load.

[0040] When a furnace or other vessel is charging (which means adding solid aluminum to the molten metal in a vessel), or when the molten metal temperature is relatively low or dropping in a vessel, the pump 22 should generally run faster to increase the solid metal melt rate and/or molten metal mixing rate. The pump 22 can be slowed when the measured temperature is proper and/or a vessel is not being charged with solid aluminum. Utilizing a slower speed when a higher speed is not necessary increases the life of pump components such as the rotor shaft 42 and rotor 100.

[0041] Some benefits of the teachings of this disclosure are one or more of: (1) increased production from an existing molten metal processing vessel; (2) increased solid metal melting efficiency; (3) more uniform temperature distribution in a vessel; (4) longer component life for the pump; and (5) less time required of a human operator.

[0042] Thermocouples in the drawings are designated by the letter “T” followed by a numeral. Vibration sensors are designated by the letter “V” followed by a numeral. Molten metal level detectors are designated by the letter “D” followed by a numeral. Scales are designated by the letter “W” followed by a numeral.

[0043] Referring now to the drawings where the purpose is to illustrate and describe non-limiting embodiments of this disclosure, FIG. 1 shows system 10 having a molten metal pump 22 that includes a rotor (also called an “impeller”) 100. Pump 22 may be positioned in molten metal M in a pump well, which may be part of the open well of a reverberatory furnace.

Exemplary Molten Metal Pump

[0044] The components of exemplary pump 22, including rotor 100, that are exposed to the molten metal are preferably formed of structural refractory materials, which are resistant to degradation in the molten metal. Pump 22 can be any structure or device for pumping or otherwise conveying molten metal, and may be an axial pump having an axial, rather than tangential, discharge.

[0045] Molten metal pump 22 can be a constant speed pump but is most preferably a variable speed pump. Its speed can be varied depending on any of one or more of the amount or temperature, of molten metal in a structure, such as a furnace, ladle or launder, or whether solid metal scrap must be melted, or the pump vibration, or of other inputs to controller 170.

[0046] Preferred pump 22 has a pump base (also called a “casing” or “housing”) 24 for being submersed in a molten metal bath. Pump base 24 preferably includes a generally nonvolute pump chamber 26, such as a cylindrical pump chamber or what has been called a “cut” volute, although pump base 24 may have any suitable shape pump chamber, including a volute-shaped pump chamber. Pump chamber 26 may be constructed to have only one opening, either in its top or bottom, if a tangential discharge is used, since only one opening is required to introduce molten metal to enter pump chamber 26. Generally, pump chamber 26 has two coaxial openings of the same diameter and usually one is blocked by a flow blocking plate mounted on the bottom of, or formed as part of, rotor 100. As shown, pump chamber 26 includes a top opening 28, bottom opening 29, and wall 31.

[0047] Base 24, in this embodiment, further includes a tangential discharge 30 in fluid communication with pump chamber 26. A preferred base 24 has sides 112, 114, 116, 118 and 120 and a top surface 110. The invention is not limited to any particular type or configuration of base, however. A pump base used with the invention could be of any suitable size, design or configuration. The top portion of wall 31 is machined to receive a bearing surface, which (in this Figure) is not yet mounted to wall 31. The bearing surface is typically comprised of ceramic and cemented to wall 31.

[0048] One or more support post receiving bores 126 are formed in base 24 and are for receiving support posts 34.

[0049] As shown in FIG. 2, pump base 24 can have a stepped surface 40 defined at the periphery of pump chamber 26 at inlet 28 and a stepped surface 40A defined at the periphery of inlet 29. Stepped surface 40 preferably receives a bearing ring member 60 and stepped surface 40A preferably received a bearing ring member 60A. Each bearing member 60, 60A is preferably comprised of silicon carbide, although any suitable material may be used. The outer diameter of members 60, 60A varies with the size of the pump, as will be understood by those skilled in the art. Bearing members 60, 60A each has a preferred thickness of 1″. Preferably, bearing ring member 60 is provided at inlet 28 and bearing ring member 60A is provided at inlet 29, respectively, of pump base 24. Alternatively, bearing ring members 60, 60A need not be used. In the preferred embodiment, bottom bearing ring member 60A includes an inner perimeter, or first bearing surface, 62A, that aligns with a second bearing surface and guides rotor 100 as described herein. It is most preferred that a bearing surface with one or more grooves, such as the surface on bearing member 150 described herein be utilized. Additionally, rotor 100 may include a bearing ring, bearing pin or bearing members, such as the ones disclosed in U.S. Pat. No. 6,093,000 to Cooper

[0050] One or more support posts 34 connect pump base 24 to a superstructure 36 of pump 22 thus connecting superstructure 36 to pump base 24. In a preferred embodiment, post clamps 35 secure support posts 34 to superstructure 36. Any suitable structure or structures capable of connecting superstructure 36 to pump base 24 may be used. Additionally, pump 22 could be constructed so there is no physical connection between the base and the superstructure. The motor, drive shaft and rotor could be suspended without a superstructure, and there need not be a pump base.

[0051] A motor 40, which can be any structure, system or device suitable for driving pump 22, but is preferably an electric or pneumatic motor, is positioned on superstructure 36 and is connected to a first end of a drive shaft 42. Motor 40 preferably is at least partially surrounded by a cooling shroud 41. Some pumps that may be used with the invention are shown in U.S. Pat. Nos. 5,203,681, 6,123,523, and 6,354,964 to Cooper.

[0052] A drive shaft 42 can be any structure suitable for connecting motor 40 to rotor 100, and for rotating rotor 100. Drive shaft 42 preferably comprises a motor shaft 42A coupled by a coupling 43 to a rotor shaft 44. The motor shaft 42A has a first end and a second end, wherein the first end of the motor shaft 42A is connected to motor 40 and the second end of the motor shaft 42A is connected to coupling 43. Rotor shaft 44 has a first end 44A and a second end 44B, wherein the first end 44A is connected to the coupling 43 and the second end 44B is connected to rotor 100.

[0053] One preferred rotor 100 is sized to fit through both openings 28 and 29, although it could be of any suitable shape or size suitable to be used in a molten metal pump. The preferred dimensions of rotor 100 will depend upon the size of pump 22 because the size of a rotor invention varies with the size of the pump and on manufacturer's specifications. Rotor 100 can be comprised of a single material, such as graphite or ceramic, or can be comprised of different materials. For example, inlet structure 104 may be comprised of ceramic and the displacement structure 102 may be comprised of graphite, or vice versa. Any part or all of rotor 100 may also include a protective coating.

[0054] As rotor 100 is rotated by drive shaft 42, displacement structure 102 and inlet structure 104 rotate. Thus, in the preferred embodiment, rotor blades 102A, 102B and 102C and inlets 106A, 106B and 106C rotate as a unit.

Exemplary System

[0055] Turning to FIGS. 4-8, an exemplary smart pump system 10′ for moving molten metal M onto a raised structure 20, such as a launder, as shown. This exemplary system 10′ includes a furnace 1 that can retain molten metal M, which in this embodiment includes a holding furnace 1A, a vessel 12, raised structure 20, and pump 22. Vessel 12 is divided by a dividing wall 14 to separate vessel 12 into at least a first chamber 16 and a second chamber 18. Pump 22 generates a stream of molten metal from first chamber 16 into second chamber 18. In system 10′, pump 22 is preferably a circulation pump (most preferred) or gas-release pump that generates a flow of molten metal from first chamber 16 to second chamber 18 through an opening 14A.

[0056] Using heating elements (not shown in the figures), furnace 1 is raised to a temperature sufficient to maintain the metal therein (usually aluminum or zinc) in a molten state. The level of molten metal M in holding furnace 1A and in at least part of vessel 12 changes as metal is added or removed to furnace 1A, as can be seen in FIG. 2.

[0057] For explanation, furnace 1 includes a furnace wall 2 having an archway 3. Archway 3 allows molten metal M to flow into vessel 12 from holding furnace 1A. In this embodiment, furnace 1A and vessel 12 are in fluid communication, so when the level of molten metal in furnace 1A rises, the level of molten metal also rises in at least part of vessel 12. It most preferably rises and falls in first chamber 16, described below, as the level of molten metal rises or falls in furnace 1A. This can be seen in FIG. 5.

[0058] As previously mentioned, dividing wall 14 separates vessel 12 into at least two chambers, a pump well (or first chamber) 16 and a skim well (or second chamber) 18, and any suitable structure for this purpose may be used as dividing wall 14. As shown in this embodiment, dividing wall 14 has planar sides, a top edge, an opening 14A, and an optional overflow spillway 14B (best seen in FIG. 6), which is a notch or cut out in the upper edge of dividing wall 14. Overflow spillway 14B is any structure suitable to allow molten metal to flow from second chamber 18, past dividing wall 14, and into first chamber 16 and, if used, overflow spillway 14B may be positioned at any suitable location on wall 14. The purpose of optional overflow spillway 14B is to prevent molten metal from overflowing the second chamber 18, or a launder 20 in communication with second chamber 18 (if a launder is used with the invention), by allowing molten metal in second chamber 18 to flow back into first chamber 16. Optional overflow spillway 14B would not be utilized during normal operation of system 10 and is to be used as a safeguard if the level of molten metal in second chamber 18 improperly rises to too high a level.

[0059] In the embodiment shown in FIGS. 4-8, overflow spillway 14B has a height H1 and the rest of dividing wall 14 has a height greater than H1. Alternatively, dividing wall 14 may not have an overflow spillway, in which case all of dividing wall 14 could have a height H1, or dividing wall 14 may have an opening with a lower edge positioned at height H1, in which case molten metal could flow through the opening if the level of molten metal in second chamber 18 exceeded H1. H1 should exceed the highest level of molten metal in first chamber 16 during normal operation.

[0060] Second chamber 18 has a portion 18A, which has a height H2, wherein H2 is less than H1 (as can be best seen in FIG. 7) so during normal operation molten metal pumped into second chamber 18 flows past wall 18A and out of second chamber 18 rather than flowing back over dividing wall 14 and into first chamber 16.

[0061] Dividing wall 14 may also have an opening 14A that is located at a depth such that opening 14A is submerged within the molten metal during normal usage. Opening 14A preferably has an area of between 6 in..sup.2 and 24 in..sup.2 but could be any suitable size. The opening 14A is preferably entirely below the level that is 50% of the height, or 40% of the height, or 30% of the height, or 20% of the height, of dividing wall 14. Further, dividing wall 14 need not have an opening if a transfer pump were used to transfer molten metal from first chamber 16, over the top of wall 14, and into second chamber 18 as described below.

[0062] Dividing wall 14 may also include more than one opening between first chamber 16 and second chamber 18, and opening 14A (or the more than one opening) could be positioned at any suitable location(s) in dividing wall 14 and be of any size(s) or shape(s) to enable molten metal to pass from first chamber 16 into second chamber 18.

[0063] Utilizing system 10, as pump 22 pumps molten metal from first chamber 16 into second chamber 18, the level of molten metal in chamber 18 rises.

[0064] A system according to this disclosure could also include one or more pumps in addition to pump 22, in which case the additional pump(s) may circulate molten metal within first chamber 16 and/or second chamber 18, or from chamber 16 to chamber 18, and/or may release gas into the molten metal first in first chamber 16 or second chamber 18. For example, first chamber 16 could include pump 22 and a second pump, such as a circulation pump or gas-release pump, to circulate and/or release gas into molten metal M.

[0065] If pump 22 is a circulation pump or gas-release pump, it may include a snout on the pump base that is at least partially received in opening 14A in order to help maintain a relatively stable level of molten metal in second chamber 18 during normal operation and to allow the level in second chamber 18 to rise independently of the level in first chamber 16. The snout could be connected in opening 14A to form a tight seal.

[0066] As shown in FIGS. 4-8, raised structure 20 in this embodiment is a launder. If raised structure 20 is a launder, it may be either an open or enclosed channel, trough or conduit, and may be of any suitable dimension or length, such as one to four feet long, or as much as 100 feet long or longer. The launder may be completely horizontal or may slope gently upward or downward. The launder may have one or more taps (not shown), i.e., small openings stopped by removable plugs. Each tap, when unstopped, allows molten metal to flow through the tap into a ladle, ingot mold, or other structure. The launder may additionally or alternatively be serviced by robots or cast machines capable of removing molten metal M from the launder.

[0067] In this embodiment, launder 20 has a first end 20A and a second end 20B. An optional stop may be included in a launder 20 juxtaposed the second end 20B. If launder 20 has a stop, the stop can be opened to allow molten metal to flow past end 20B or closed to help prevent molten metal from flowing past end 20B.

[0068] FIG. 8 shows an alternate system 10′ that is in all respects the same as system 10 except that it has a shorter, downward, sloping launder 20′, wall 18A′ past which molten metal moves when it exits second chamber 18, and it fills a ladle 52.

Exemplary Smart Pump/System Features

[0069] An exemplary smart pump system 10 or 10′ according to this disclosure includes pump 22, and a controller 170 for controlling the speed of the pump, and further includes one or more of: (1) one or more thermocouples (which could be any device for measuring temperature) to measure molten metal temperature at one or more locations; (2) one or more devices (referred to herein sometimes as a “depth device”), such as a laser or float, to measure the depth (or level) of molten metal in one or more structures; and (3) one or more vibration sensors, such as an accelerometer(s), to measure vibration of the pump and/or one or more pump components, such as the rotor 100 and/or rotor shaft 44. The controller 170 receives a measured input (or “input” or “communication”) from one or more of: (a) the thermocouple(s) about the temperature of the molten metal at one or more locations; (b) the depth device(s) about the depth (or level) of the molten metal at one or more locations; and (c) the vibration sensor(s) about the vibration of the pump, and/or of one or more pump components. The controller may also receive input about one or more of: the pump speed, pump load, the length of time the pump has been operating, prior maintenance performed on the pump, and the weight of molten metal in structures, such as a launder, mold, or other vessel. The controller can analyze the one or more inputs to turn the pump on, to vary the speed of the pump, to turn the pump off, and/or send messages to an operator.

[0070] The thermocouple(s) is preferably configured to be positioned at a location in which it is under the surface of the molten metal when the molten metal pump is operating. The thermocouple may be positioned in a support post, pump base, rotor, or rotor shaft of the molten metal pump and housed so that it is not directly exposed to molten metal. As shown in the example in the Figures, there is a thermocouple T1 mounted in a support post 34, a thermocouple T2 mounted in base 24, a thermocouple T3 mounted in rotor 100, a thermocouple T4 positioned in second chamber 18, a thermocouple T5 positioned in vessel 1, and a thermocouple T6 positioned in a side wall of launder 20. Controller 170 may receive input from one or more of these thermocouples, and/or from one or more other thermocouples positioned at different locations.

[0071] The system 10 may also include one or more depth devices. As shown in the example, there is a depth device D1 on the pump superstructure 36 that measures the depth (or level) of molten metal in the vessel (which for D1 is the level of molten metal in first chamber 16) in which molten metal pump 22 is positioned. A depth device D2 is positioned above launder 20 and may be mounted on a side wall of launder 20 and measures the level of molten metal in the launder 20. A depth device D3 is positioned above vessel 1 and may be mounted on a side wall of vessel 1 and measures the level of molten metal in vessel 1. A depth device D4 is above ladle 52 and measures the level of molten metal in ladle 52. Controller 170 may receive input from one or more of the depth devices, and/or from other depth devices positioned at different locations.

[0072] The system 10 may also include one or more vibration sensors. A vibration sensor, which may be an accelerometer, V1 is shown in this example as being positioned on drive shaft 44. A vibration sensor V2 is shown as being positioned in rotor 100. Controller 170 may receive input from one or more of the vibration sensors, and/or from other vibration sensor(s) positioned at different locations.

[0073] The system may also include one or more weight sensors, which may be scales, to measure the weight of molten metal in one or more structures. In the example shown, there is a weight sensor W1 that measures the weight of molten metal in ladle 52. A weight sensor W2 measures the weight of molten metal in molds 52′ on a fill line. Controller 170 may receive input from one or more of the weight sensor(s), and/or from weight sensor(s) positioned at different locations.

[0074] All the pump information can optionally be shared to a user's computer 500 or hand-held electronic device 510, so the user can view it at his/her office, at home, or any remote location. The pump operational and input information can also be stored over time, for troubleshooting the pump, the vessel in which the pump operates, and/or the operational system and method used at the processing facility. In addition, software can make it possible for a computer 520 at the pump manufacturer to remotely access the controller 170 in order to troubleshoot or modify the operation of pump 22.

Exemplary Controller

[0075] FIGS. 10-13 show a controller, 170 which could function with any system according to this disclosure. The controller 170 may be positioned on the superstructure 36 or be remote to the pump 22 and communicate through a wired or wireless connection with the pump and sensors described herein.

[0076] The controller 170 may vary the speed of, and/or turn off and on, molten metal pump 22, or send a message to an operator, in accordance with any of the inputs. For example, if the input was the amount of molten metal in a ladle (as measured by any device, such as a scale or laser), when the amount of molten metal M within the ladle is low, the controller 170 could cause the speed of molten metal pump 22 to increase to pump molten metal M at a greater flow rate to fill the ladle. As the level of the molten metal within the ladle increased, the controller could cause the speed of molten metal pump 22 to decrease and to pump molten metal M at a lesser flow rate, thereby decreasing the flow of molten metal into the ladle. The controller 170 could be used to stop the operation of molten metal pump 22 should the amount of the molten metal within a structure, such as a ladle, reach a given value or if a problem were detected. The control system could also start pump 22 based on a given input.

[0077] The controller may provide proportional control, such that the speed of molten metal pump 22 is proportional, or varied, according to one or more of: (1) the amount (or level) of molten metal within one or more vessels; (2) the temperature of molten metal within one or more vessels; (3) the amount of solid aluminum being added to one or more vessels; (4) the weight of molten metal in one or more vessels; (5) the vibration of the pump of one or more pump components, (6) the pump speed; and (7) the pump load. The controller could be customized to provide a smooth, even flow of molten metal to one or more structures such as one or more ladles or ingot molds with minimal turbulence and little chance of overflow.

[0078] FIG. 13 shows a control panel 70 that may be used with a controller. Controller 170 includes an “auto/man” (also called an auto/manual) control 172 that can be used to choose between automatic and manual control. A “device on” button 174 allows a user to turn any sensors or inputs on and off. An optional “metal depth” indicator 176 allows an operator to determine the depth of the molten metal as measured by the depth devices. An emergency on/off button 178 allows an operator to stop metal pump 22. An optional RPM indicator 180 allows an operator to determine the number of revolutions per minute of rotor 100 of molten metal pump 22. An AMPS indicator 182 allows the operator to determine an electric current to the motor of molten metal pump 22. A start button 184 allows an operator user to start molten metal pump 22, and a stop button 185 allows a user to stop molten metal pump 22.

[0079] A speed control 186 can override the automatic controller 170 (if being utilized) and allows an operator to increase or decrease the speed of the molten metal pump 22. A cooling air button 190 allows an operator to direct cooling air to the pump motor.

[0080] Some non-limiting examples of this disclosure are as follow:

[0081] Example 1: A molten metal pump system comprising:

[0082] a controller for controlling the speed of the pump;

[0083] a thermocouple positioned in one of the base, support post, rotor, or rotor shaft, wherein the thermocouple is configured to measure the temperature of molten metal in which the pump is positioned and communicate the temperature to the controller;

[0084] a laser mounted on the superstructure, the laser configured to measure the depth of molten metal in the vessel and to communicate the depth to the controller;

[0085] wherein the controller varies the speed of the pump based on the temperature of the molten metal and the depth of the molten metal in the vessel.

[0086] Example 2: The molten metal pump system of example 1 that comprises a circulation pump.

[0087] Example 3: The molten metal pump system of example 1 that comprises a gas-release pump.

[0088] Example 4: The molten metal pump system of example 1 that comprises a gas-release pump that releases gas directly into the pump chamber.

[0089] Example 5: The molten metal pump system of example 1 that comprises a transfer pump.

[0090] Example 6: The molten metal pump system of example 1 that comprises a transfer pump that has a riser tube comprising a first end connected to the pump base and a second end connected to a launder.

[0091] Example 7: The molten metal pump system of example 1 that further comprises a vibration sensor on one or more of the rotor shaft, the superstructure, and the rotor, wherein the vibration sensor is configured to detect vibration and communicate the vibration to the controller.

[0092] Example 8: The molten metal pump system of example 7, wherein the controller is programmed with a maximum vibration level and the controller is configured to turn off the molten metal pump system if the maximum vibration level is exceeded.

[0093] Example 9: The molten metal pump system of any of examples 1-8, wherein the controller is remote to the pump.

[0094] Example 10: The molten metal pump system of any of examples 1-8, wherein the controller is on a superstructure of the pump.

[0095] Example 11: The molten metal pump system of any of examples 1-10, wherein the thermocouple is in an enclosed box that is configured to be positioned beneath the molten metal when the molten metal pump system is positioned in a molten metal bath, so the thermocouple does not contact the molten metal.

[0096] Example 12: The molten metal pump system of any of examples 1-11, wherein there is an insulating material between the superstructure and the laser.

[0097] Example 13: The molten metal pump system of any of examples 1-12, wherein the thermocouple is positioned in the vessel and is remote from the pump.

[0098] Example 14: The molten metal pump system of any of examples 1-13, wherein the communication from the thermocouple to the controller is wireless.

[0099] Example 15: The molten metal pump system of any of examples 1-14, wherein the communication from the laser to the controller is wireless.

[0100] Example 16: The molten metal pump system of example 7, wherein the communication from the vibration sensor to the controller is wireless.

[0101] Example 17: The molten metal pump system of example 1 that further comprises a display that shows one or more of: a measured temperature of the molten metal, a measured depth of the molten metal, a vibration level of the molten metal pump, a load on the pump, and a speed of the molten metal pump.

[0102] Example 18: The molten metal pump system of any of examples 1-17, wherein the controller comprises a memory that stores an operational history of the molten metal pump.

[0103] Example 19: The molten metal pump system of any of examples 1-18, wherein the controller can be accessed from a remote location.

[0104] Example 20: The molten metal pump system of example 19, wherein the controller can be re-programmed from the remote location.

[0105] Example 21: The molten metal pump system of example 7 or 16, wherein the vibration sensor is an accelerometer.

[0106] Example 22: The molten metal pump system of any of examples 1-21, wherein there is an insulating material configured to be between the superstructure and a molten metal bath when the molten metal pump is in a molten metal bath.

[0107] Example 23: The molten metal pump system of any of examples 1-22, wherein the controller: varies the speed of the pump, turns off the pump, and/or sends a message to a monitor or operator, based on (a) the temperature of the molten metal, (b) the depth of the molten metal, and/or (c) the vibration of the pump.

[0108] Example 24: The molten metal pump system of any of examples 1-23, wherein the controller is further configured to receive one or more of the pump speed and pump load and wherein the controller: varies the speed of the pump, turns off the pump, and/or sends a message to a monitor or operator, based on (a) the temperature of the molten metal, (b) the depth of the molten metal measured, (c) the speed of the pump, and/or (d) the pump load.

[0109] Example 25: The molten metal pump system of any of examples 1-24 that further comprises a second thermocouple in the vessel and remote to the pump, the second thermocouple being in communication with the controller.

[0110] Example 26: The molten metal pump system of any of examples 1-25 that further comprises a second depth device mounted and configured so as to measure the depth of molten metal in a second vessel, the second depth device being in communication with the controller.

[0111] Example 27: The molten metal pump system of any of examples 1-26 that further comprises a scale that measures the weight of molten metal in a structure and communicates the weight to the controller.

[0112] Example 28: The molten metal pump system of any of examples 1-27 that further comprises a second vibration sensor on or in a pump structure that does not include the vibration sensor.

[0113] Example 29: The molten metal pump system of example 26, wherein the second vessel is a ladle, a launder, a mold, or a reverberatory furnace.

[0114] Example 30: The molten metal pump system of example 27, wherein the structure is a ladle or a mold.

[0115] Example 31: The molten metal pump system of example 28, wherein the vibration sensor is on the pump shaft and the second vibration sensor is in the rotor.

[0116] Having thus described different embodiments of the invention, other variations and embodiments that do not depart from the spirit thereof 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 product or result.