Quick submergence molten metal pump

Abstract

A pump for transferring molten metal includes an intake tube, a motor, a rotor positioned at least partially within the bottom end of the intake tube, a rotor shaft positioned at least partially in the intake tube, the rotor shaft having a first end attached to the motor and a second end attached to the rotor. An overflow conduit is attached to the intake tube. The pump does not include a pump housing and preferably does not include a superstructure, so it is relatively small, light and portable. In use, the motor drives the rotor shaft and rotor to generate a flow of molten metal upward into the intake tube and into the overflow conduit where it is discharged.

Claims

1. A pump for transferring molten metal from a vessel, the system comprising: (a) a stationary intake tube, the stationary intake tube having an inner diameter and configured for directing molten metal upward through the stationary intake tube, the stationary intake tube including a first end configured for being at least partially submerged in the molten metal in the vessel, and a second end; (b) an intake tube extension having a first end connected to the second end of the stationary intake tube and having a second end; (c) a motor juxtaposed the second end of the intake tube extension; (d) a rotatable drive shaft positioned at least partially within the stationary intake tube, the rotatable drive shaft not directly connected to the stationary intake tube, and being partially submersed in molten metal while the pump is operating, and having a first end connected to the motor and a second end; (e) a rotor positioned at least partially in the first end of the stationary intake tube, the rotor being directly connected to the second end of the rotatable drive shaft and extending outwardly from the rotatable drive shaft, the rotor having a diameter that is less than the diameter of the stationary intake tube, the rotor not directly connected to the stationary intake tube, and the rotor having an outer perimeter wherein there is a space between the outer perimeter of the rotor and the stationary intake tube; (f) an enclosed overflow conduit coupled to the intake tube extension above the rotor, below the motor, above the stationary intake tube, and above the first end of the intake tube extension, the enclosed overflow conduit configured for directing molten metal out of the stationary intake tube; and wherein the rotatable drive shaft and rotor are configured to be rotated by the motor to rotate inside of the stationary intake tube in order to push molten metal upward into the stationary intake tube, immersing part of the drive shaft in the molten metal inside of the stationary intake tube, while the stationary intake tube remains stationary.

2. The pump of claim 1, wherein the enclosed overflow conduit is removably coupled to a second section of the stationary intake tube.

3. The pump of claim 1 that does not include a pump casing including a pump chamber in which the rotor is positioned.

4. The pump of claim 1 that does not include a superstructure that supports the motor.

5. The pump of claim 1 further comprising a support structure configured for positioning and supporting the pump within the vessel.

6. The pump of claim 5 wherein the support structure comprises a chain attached to the pump.

7. The pump of claim 6 wherein the chain is coupled to a hook on the pump.

8. The pump of claim 1 wherein the stationary intake tube has a length and the inner diameter is uniform throughout the length.

9. The pump of claim 1 wherein the enclosed overflow conduit has an inner diameter and the inner diameter of the stationary intake tube is different from the inner diameter of the enclosed overflow conduit.

10. The pump of claim 1 wherein the rotor is centered in the stationary intake tube.

11. The pump of claim 1 wherein the rotatable drive shaft is centered in the stationary intake tube.

12. The pump of claim 1 wherein the rotor has an outer diameter, and the outer diameter of the rotor is 0.03 inches or less than the inner diameter of the stationary intake tube.

13. The pump of claim 1 wherein the motor is selected from the group consisting of: an electric motor; a pneumatic motor, and a hydraulic motor.

14. The pump of claim 1 wherein the stationary intake tube comprises one or more gates at the first end, the one or more gates configured to prevent the stationary intake tube from adhering to a surface of the vessel.

15. The pump of claim 1 further comprising one or more bearings on one or more of the rotor and the first end of the stationary intake tube.

16. The pump of claim 15 wherein the one or more bearings are comprised of ceramic.

17. The pump of claim 1 wherein the second end of the stationary intake tube comprises an inner diameter of between 3 inches and 9 inches.

18. The pump of claim 1 wherein the stationary intake tube comprises graphite.

19. The pump of claim 1 wherein the stationary intake tube comprises ceramic.

20. The pump of claim 1 wherein the enclosed overflow conduit comprises one or more of the group consisting of graphite, ceramic and steel.

21. The pump of claim 1 wherein the stationary intake tube has an inner surface and includes insulation on its inner surface.

22. The pump of claim 1 wherein the enclosed overflow conduit has an inner surface and includes insulation on its inner surface.

23. The pump of claim 1 wherein the rotor is a dual-flow rotor configured to push molten metal upward into the stationary intake tube, wherein the dual-flow rotor has a plurality of blades, wherein each blade has a first section that pushes the molten metal upwards into the stationary intake tube and a second section above the first section, wherein the second section is configured to push molten metal outwards.

24. The pump of claim 1 wherein the stationary intake tube has' further includes a circular cross section.

25. The pump of claim 1 wherein the stationary intake tube has' further includes a rectangular cross section.

26. The pump of claim 25 wherein the stationary intake tube has a plurality of sides, and each side of the stationary intake tube has an inner surface, and each inner surface has a length of between 3 and 9.

27. The pump of claim 1 wherein the drive shaft comprises a motor shaft coupled to a rotor shaft, wherein the motor shaft includes a motor shaft first end connected to the motor, and the rotor shaft includes a rotor shaft second end connected to the rotor.

28. The pump of claim 27 wherein the rotor shaft is comprised of one or more of ceramic or graphite.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1 and 2 illustrate partial, cross-sectional side views of a pump for pumping molten metal from a vessel in accordance with the present invention.

(2) FIG. 3 is a partial, side view of the pump of FIGS. 1 and 2 that is utilized to fill a ladle using a launder.

(3) FIG. 4 shows a perspective view of an alternative embodiment of a pump according to aspects of the present invention.

(4) FIG. 5 shows a perspective view of a rotor in accordance with the present invention.

(5) FIGS. 6A and 6B illustrate a support structure for supporting the pump of present invention in a vessel.

(6) FIGS. 7A-7K illustrate various views of an alternate embodiment of a pump according to various aspects of the present invention.

(7) FIGS. 8A-8C illustrate perspective, top, and side views, respectively, of an alternate rotor in accordance with the present invention.

(8) FIGS. 9A and 9B illustrate another exemplary embodiment of the present invention.

(9) FIG. 9C is a cross-sectional side view of the embodiments of FIG. 9B taken through lines A-A.

(10) FIG. 9D is an assembled perspective, front view of the embodiment of FIG. 9A-9B.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(11) Turning now to the Figures, where the purpose is to describe preferred embodiments of the invention and not to limit same, FIGS. 1, 2, and 3 show an exemplary pump 10 for transferring molten metal 1 from one or more vessels 20 according to the present invention. The present invention may be utilized to transfer molten metal 1 from one vessel (such as a ladle or pump well) to another vessel (such as a launder, and/or ladle) or any desired structure. Pump 10 includes an intake tube 30, an overflow conduit 50, and a motor 70.

(12) In the embodiment of the present invention depicted in FIGS. 1-3, the intake tube 30 includes a first end 31 and a second end 45. The intake tube 30 is preferably fabricated from structural refractory materials, such as graphite (most preferred) or ceramics, that are resistant to disintegration by corrosive attack from the molten metal 1. The intake tube 30 can be formed from multiple portions, may include insulation (such as FIBERFRAX insulation manufactured by Carborundum Co.) on its inside wall and may be of any suitable size, shape, or configuration. The first end 31 of the intake tube 30 is fabricated to be at least partially submersible in molten metal 1 contained in vessel 20.

(13) The open end of the first end 31 of the intake tube 30 can be any suitable shape but is preferably circular or rectangular. In the embodiment depicted in FIGS. 1-3, intake tube 30 forms a cylinder. Though any suitable dimension or dimensions may be employed, the preferred internal diameter of the intake tube 30 is between about 3 inches to about 9 inches.

(14) The diameter of the intake tube 30 can vary between the first end 31 and the second end 45. For example, the diameter of the intake tube 30 may increase or decrease between the first end 31 and the second end 45. Additionally, the intake tube 30 may include one or more portions of a different diameter than either the first end 31 or the second end 45. Among other things, varying the dimensions of the intake tube 30 can aid in controlling the flow and/or pressure of the molten metal 1 through the pump 10. FIGS. 7A-7K illustrate an alternate embodiment of a pump according to various aspects of the present invention. In this embodiment, the intake tube 30 includes an insulating sleeve 710 (as shown in FIG. 7A).

(15) The length of the intake tube 30 between the first end 31 and the second end 45 may be any suitable dimension to transfer molten metal from a vessel. In the exemplary embodiment depicted in FIGS. 1-3, the preferred length between the first end 31 and the second end 45 of the intake tube 30 is between about 24 and about 48 inches. The dimensions of the intake tube can be adjusted to accommodate the depth of the vessel 20, and/or to minimize the amount of surface area the molten metal 1 must travel in the pump 10 outside of the molten metal bath so that the metal does not cool and re-harden.

(16) The wall of the intake tube 30 may be any desired thickness, and need not be the same thickness at all points along the intake tube 30. In the embodiment depicted in FIGS. 1-3, for example, the preferred wall thickness of the intake tube 30 is about inch along the length of the intake tube 30.

(17) Referring to FIG. 2, the first end 31 of the intake tube is notched with a plurality of gates 32. One benefit of the gates 32 is to prevent the suction generated by the rotor 80 from causing the first end 31 to become stuck to a flat surface of the vessel 20. In alternate embodiments of the present invention, the first end 31 can be shaped to accommodate features of the vessel 20, such as tight chamber and/or corner. Alternatively, in yet another embodiment, the first end 31 may be fitted with an attachment to reach difficulty accessed regions of a vessel. The attachment may be formed out of any suitable material and may be any size, shape, and configuration for transferring molten metal from a vessel 20. For example, the attachment may be formed from material having substantially similar thermal properties as other portions of the pump 10 to eliminate or reduce the need to preheat the pump 10 to transfer the molten metal 1.

(18) The second end 45 of the intake tube 30 can be coupled to an intake tube extension 40 in any suitable manner. The intake tube extension 40 and the intake tube 30 may be the same structure or they may comprise two independent structures. The intake tube extension 40 can be fabricated out of a robust material suitable to withstand the stress of the system components, such as graphite or insulated steel. In the present embodiment, the intake tube extension 40 is formed from steel with its interior surface lined with suitable insulation. In the present embodiment, Fiberfrax alumino-silicate refractory ceramic fiber products, manufactured by Unifrax Corporation, are used. Fiberfrax high temperature insulation is available in over 50 woven and non-woven product forms, to meet a variety of specific thermal management needs, at temperatures up to 1430 C. (2600 F.).

(19) The opening of the intake tube extension 40 and the second end 45 of the intake tube 30 can be coupled together in any manner. In the present exemplary embodiment, the intake tube 30 is flanged, creating a slightly wider diameter to accept the intake tube extension 40. Alternately, the intake tube extension 40 could be flanged to accept the intake tube 30. In the present embodiment, the flanged second end 45 of the intake tube 30 includes three metal receiving holes (not shown) for receiving a threaded machine bolt. These receiving holes are placed at 120 degree intervals around the external surface of the second end 45 of intake tube 30. These receiving holes correspond to receiving holes placed at 120-degree intervals fixed to the exterior surface of the intake tube extension 40. In the present embodiment, the two components are held in place using three hex head machine bolts, lock washers and a nut. Any other suitable fastener(s) may also be utilized. A sealant, such as cement (which is known to those skilled in the art), may be used to seal intake tube extension 40 and intake tube 30, although it is preferred that the tube extension 40 and intake tube 30 are configured to fit together tightly without the use of such sealant. Among other things, this allows for the tube extension 40 and intake tube 30 to be uncoupled for servicing without having to chisel away the old cement, and without having to wait for new cement to cure before being able to use the pump 10.

(20) The overflow conduit 50 can branch off from the intake tube extension and/or intake tube (40, 30). In the embodiment depicted in FIGS. 1-3, this branch occurs at a substantially 90 degree angle, though other angles may be used (as described below). The overflow conduit 50 can be any size or shape. Though it may be manufactured out of any suitable material, in one embodiment, the overflow conduit 50 is made of the same material as the intake tube extension 40 to help reduce or eliminate the need to preheat the pump 10 before transferring molten metal. In the present exemplary embodiment, the overflow conduit 50 is formed from insulated steel as described above.

(21) The overflow conduit 50 may be part of the same structure as the intake tube extension 40, or it may be part of a separate structure from the intake tube extension 40. In one embodiment, the overflow conduit 50 is welded to the intake tube extension 40 in a fixed position. The overflow conduit 50 may be any size and shape. In the present exemplary embodiment, the overflow conduit 50 is substantially cylindrical. In this embodiment, the overflow conduit is about 12 inches to about 36 inches long, with an inner diameter of between about 5 inches to about 8 inches, and with an outer diameter of about 6 inches to about 9 inches. The overflow conduit 50 may include a plug or closable barrier to obstruct the unwanted flow of molten metal 1.

(22) In one embodiment, at least one opening is formed in the intake tube extension 40 above the level of the overflow conduit 50, where a user can inspect one or more of: the motor shaft 60, motor shaft coupler 65, the interior of the overflow conduit 50, and/or the rotor shaft 85. In the present embodiment, the intake tube extension 40 has two 5 inch by 5 inch openings in the intake tube extension 40. The motor 70 is housed above these openings, and is centered on the top external surface of the intake tube extension 40. The openings can be any suitable size, shape and configuration to allow inspection and/or access to the components of the pump 10.

(23) The motor 70 may be coupled to the intake tube extension 40 and/or intake tube in any suitable manner. In one embodiment, Referring to FIGS. 6A and 6B, the motor 70 is attached using an L bracket 610. The external horizontal surface of the L bracket 610 is affixed to the top horizontal surface of the intake tube extension 40 and the motor 70 is coupled to the interior vertical surface of the L bracket 610.

(24) The pump 10 may be temporarily or permanently affixed to a support structure. For example, the pump 10 can be coupled to a horizontal pole in order to transfer molten metal from a single location. In another embodiment, referring again to FIGS. 6A and 6B, the support structure includes a chain 620 attached to the top of the L bracket 610. In this embodiment, the L bracket 610 includes an eyehook 615 through which the chain 620 can be run to support the pump 10. The chain 620 may be looped over and/or around any anchoring structure capable of supporting the weight of the pump 10, such as a crane, forks on a forklift, or other portable structure. In this manner, the pump 10 can be moved from one vessel 20 to another vessel 20 (without preheating the pump 10) to quickly transfer molten metal from multiple vessels 20. The chain 620 can also be wrapped around a structural beam 630 of the facility housing the vessel. The flexibility of the chain hung pump 10 assists in absorbing jarring and reacting to pumping pressure. The portability of the present invention also allows it to be quickly introduced to remove molten metal from vessels with failed pumps.

(25) The motor 70 is capable of driving the rotor 80 at a suitable speed to transfer molten metal 1 from a vessel 20 through the overflow conduit 50 using the pump 10. The motor 70 may include an electric motor, pneumatic motor, hydraulic motor, and/or other suitable motor. In one exemplary embodiment of the present invention, the motor is a Gast Model No. 8AM pneumatic motor, with an air source (not shown) supplying air through hose 90 to drive the motor 70. The motor 70 is centered above the intake tube extension 40 and intake tube 30. Motor 70 drives a drive shaft, which is preferably comprised of a motor shaft 60 that extends into intake tube extension 40 and/or intake tube 30. The motor shaft 60 is coupled to a rotor shaft 85, wherein the motor shaft 60 has two ends, one end being connected to the motor 70, and the other end being coupled to the rotor shaft 85. The rotor shaft 85 also has two ends, wherein one end is coupled to the motor shaft 60 and the other end is connected to the rotor 80. The rotor shaft 85 is preferably comprised of graphite, the motor shaft 60 is preferably comprised of steel, and the two are coupled by a coupling, such as a motor shaft coupler 65, which is preferably comprised of steel. In one embodiment, the motor shaft 60 has about a inch diameter and is between about 2 to about 4 inches in length.

(26) The rotor shaft 85 is located inside the chamber of the intake tube 30 and intake tube extension 40 and couples to the rotor 80 at the first end 31 of the intake tube 30. Though it may be any suitable dimension, the rotor shaft 85 in the exemplary embodiment depicted in FIGS. 1-3 is preferably between about 1 and inches to about 3 inches in diameter. The diameter of the rotor shaft 85 may be dependent upon (among other things) the type of material(s) from which the rotor shaft 85 is formed. The rotor shaft 85 may be any suitable length to place the rotor 80 very near the first end 31 of the intake tube 30.

(27) The rotor 80 can be any suitable rotor 80. As the motor 70 turns the motor shaft 60, the motor shaft 60 turns rotor shaft 85, which turns the rotor 80. As the rotor 80 rotates, it forces molten metal 1 up the intake tube 30 and out the overflow conduit 50. In one embodiment, the gap between the edge of first end 31 of the intake tube 30 and the outer circumferential edge of the rotor 80 is about inch or less, and is preferably about 0.030 inch.

(28) As depicted in FIG. 5, the rotor is preferably designed for generating axial upward flow of the molten metal 1 (as shown rotor 80 is designed to rotate in a clockwise direction). In this context, upward refers to the molten metal travelling from first end 31 of the intake tube 30 towards the overflow conduit 50. In the preferred embodiment, the rotor comprises two disk faces (510, 520) connected to a central rotor shaft 85, and includes a plurality of channels 530 that span from the first face 510 to the second face 520. These channels 530 are angled so as to create vertical force which directs molten metal at least partly in the upward direction, up the intake tube 30, as shown in FIG. 3.

(29) The rotor may include any number of channels 530, and the channels may be of any size, shape, and configuration. In the present embodiment, four channels 530 are depicted in the rotor 80. The height of the rotor 80 is between about 3 inches to about 9 inches. The diameter of the rotor 80 is between about 3 inches and about 9 inches. The channels are cylindrical and each channel is approximately one inch in diameter in the embodiment shown.

(30) Alternatively, the rotor leading surface may be substantially planar or curved, or multi-faceted, such that, as rotor 80 turns, the surface directs molten metal partially in the upward direction. Any surface or structure (at any angle) that functions to direct molten metal upward or partially upward can be used, but it is preferred that the surface is formed at an angle of between about 30 degrees to about 60 degrees, and is most preferably a planar angle of about 45 degrees. An alternate rotor 800 that can be used in conjunction with the present invention is depicted in FIGS. 8A-8C.

(31) Though it is preferable to use substantially uniform materials or materials having uniform thermal properties, so that preheating is not required, in one embodiment, the inside of the first end 31 of the intake tube 30 and rotor 80 may employ a bearing system comprising ceramic, SiO.sub.2 or AlO.sub.2 rings wherein there are one or more rings on the rotor that align with rings in the inside of the first end 31 of the intake tube 30. The purpose of the bearing system is to reduce damage to the soft, graphite components, particularly the rotor 80 and first end 31, during motor 70 operation. In an alternate embodiment, there is no contact between intake tube 30 and rotor 80.

(32) Referring now to FIG. 3, the pump 10 may operate in conjunction with a launder 25. The launder 25 may comprise any structure or device for transferring molten metal from vessel 21 to one or more structures, such as one or more ladles, molds (such as ingot molds) or other structures in which the molten metal 1 is ultimately cast into a usable form, such as an ingot. Launder 25 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. Launder 25 may be temporarily fastened to the distal end of the overflow conduit 50 in any suitable manner. Launder 25 may be made out of structural refractory materials, such as graphite or ceramics, as well as any other material that is resistant to disintegration by corrosive attack from the molten metal, such as insulated steel. Launder 25 may have one or more taps, i.e., small openings stopped by removable plugs. Each tap, when unstopped, allows molten metal 1 to flow through the tap into a ladle, ingot mold, or other structure. Launder 25 may additionally or alternatively be serviced by robots or cast machines capable of removing molten metal 1 from launder 25.

(33) In the exemplary embodiment depicted in FIG. 3, the launder 25 has a first end 26 in communication with the overflow conduit 50 and a second end 27 that is opposite first end 26. The launder 25 may include a stop (not shown) removable connected to the second end 27 of the launder 25. The stop can be opened to allow molten metal to flow out of the second end 27, or closed to prevent molten metal from flowing out of the second end 27.

(34) FIG. 4 shows an alternate system 11 that is in all respects the same as pump 10 except that it includes an overflow conduit 50 extending from the intake tube extension 40 at an angle less than 90 degrees relative to the intake tube extension 40. In FIG. 4, an angle of approximately 60 degrees is depicted, though the overflow conduit 50 may be at any angle that promotes the efficient transfer of molten metal 1.

(35) The overflow conduit 50 may be at a fixed angle relative to the intake tube extension 40. Alternatively, the overflow conduit 50 may be hingably connected to the intake tube extension 40 so that flow of molten metal can be selectably directed. It is preferable that such a variable overflow conduit 50 not allow molten metal to escape from any seams between the overflow conduit 50 and the intake tube extension 30. Once a preferred angle has been selected, the overflow conduit 50 can be fixed into a desired position using, for example, a hand tightened wing nut. The overflow conduit 50 may be fixed in place in any other suitable manner. FIG. 4 also depicts a flow suppressor 52 that can be used to block the flow of molten metal 1 from exiting the overflow conduit 50. The flow suppressor 52 may be any device capable of suppressing the flow of the molten metal 1, such as a plug, cap, lid, gate, and/or door. In the exemplary embodiment depicted in FIG. 4, the flow suppressor 52 is shown as a controllable, automated gate. When the gate is closed, the operation of the motor 70 is automatically halted.

(36) When the pump 10 is formed from materials having substantially similar thermal properties, the pump 10 does not need to be preheated prior to use. This allows the pump 10 to be quickly employed to transfer molten metal 1 from a vessel 20. Molten metal 1 may be removed from a vessel 20 by inserting the first end 31 of the intake tube 30 into the vessel 20 and at least partially submerging the intake tube 30 into the molten metal 1. As discussed above, the gates 32 at the first end 31 of the intake tube 30 help prevent the intake tube 30 from becoming stuck to the vessel 20 due to the suction generated by the rotor 80. Once the pump 10 is in position, the motor 70 is activated turning the motor shaft 60, which in turn rotates the rotor shaft 85 and rotor 80. The rotation of the rotor 80 forces the molten metal 1 up through intake tube 30 and through the overflow conduit 50. The molten metal 1 exits the distal end of the overflow conduit 50. The motor 70 may be variably controlled based on the level of the molten metal 1. In one embodiment, this variable control can include on, off, and a selectable range of RPMs between on and off. The pump 10 can operate free from a base or housing, and superstructure, and it does not require support posts, making it more portable than conventional molten metal pumps.

(37) 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.