Variable method for using cloth filters in automated vertical molding

Abstract

The present invention is a method for using cloth filters in automated vertical molding, comprised of the steps of configuring a modular cloth filter setter having a housing, an upper jaw, and a lower jaw, wherein the upper jaw and lower jaw are selected to correspond to the size of a cloth filter, fixedly attaching the housing of the modular cloth filter setter to a mechanical arm, securing the cloth filter between the upper jaw and the lower jaw, creating a sand mold from a quantity of compressed sand, creating at least one print aperture for insertion of a cloth filter, and placing the cloth filter in the print aperture.

Claims

1. A method for using cloth filters in automated vertical molding, comprised of the steps of: configuring a modular cloth filter setter having a housing, an upper jaw, and a lower jaw, wherein said upper jaw and said lower jaw are selected to correspond to the size of a cloth filter; fixedly attaching said housing of said modular cloth filter setter to a mechanical arm; securing said cloth filter between said upper jaw and said lower jaw; creating a sand mold from a quantity of compressed sand; creating at least one print aperture for insertion of the cloth filter; and placing said cloth filter in said at least one print aperture.

2. The method of claim 1, wherein said at least one print aperture is located in said sand mold.

3. The method of claim 1, wherein said at least one print aperture is located between said sand mold and an inlet channel.

4. The method of claim 3, which further includes the step of diverting molten metal using said cloth filter.

5. The method of claim 4, which further includes the step of creating a barrier to form an area of low-density metal, using said cloth filter.

6. The method of claim 5, which further includes the step of forming a shear plane from said area of low-density metal, using said cloth filter.

7. The method of claim 1, which further includes the step of creating a second print aperture, wherein said second print aperture is located in said sand mold and wherein said at least one print aperture is located between said sand mold and an inlet channel.

8. The method of claim 7, which further includes the step of performing a filtering function using a filter located in said second print aperture.

9. The method of claim 7, which further includes the step of placing a ceramic filter in said second print aperture.

10. The method of claim 7, which further includes the step of placing a second cloth filter in said second print aperture.

11. The method of claim 7, which further includes the step of diverting molten metal using a cloth filter placed in said at least one print aperture.

12. The method of claim 11, which further includes the step of creating a barrier to form an area of low-density metal, using said cloth filter.

13. The method of claim 12, which further includes the step of creating a shear plane from said area of lower density metal, using said cloth filter.

14. The method of claim 1, which further includes the step of measuring a parameter selected from a group consisting of the following: time, volume, and pressure.

15. The method of claim 1, wherein said step of configuring said modular cloth filter setter further includes the step of replacing a first upper jaw and a first lower jaw with a second upper jaw and a second lower jaw.

16. The method of claim 15, wherein said second upper jaw and said second lower jaw have a size corresponding to the size of a newly selected cloth filter to be used.

17. The method of claim 1, which further includes the step of depositing a plurality of cloth filters into a filter separation box to disarrange said plurality of cloth filters and make said plurality of cloth filters easier to handle.

18. The method of claim 17, wherein said filter separation box includes a plurality of walls and a plurality of separation structures for disarranging said plurality of cloth filters and making said plurality of cloth filters easier to handle.

19. The method of claim 1, wherein said steps of creating at least one sand mold and creating at least one print aperture are performed substantially simultaneously.

20. The method of claim 1, which further includes the step of ejecting said cloth filter into said at least one print aperture with an ejection cylinder.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING(S)

(1) FIGS. 1a-1d illustrate perspective, top, front and side views, respectively, of an exemplary embodiment of a filter separation box of a system for using cloth filters in automated vertical molding.

(2) FIGS. 2a-2d illustrate perspective, top, front and side views, respectively, of an exemplary embodiment of a filter setter of a system for using cloth filters in automated vertical molding.

(3) FIGS. 3a-3e illustrate perspective, top, front, side and mounted views, respectively, of an exemplary embodiment of a filter print plate of a system for using cloth filters in automated vertical molding.

(4) FIGS. 4a-4c illustrate front, side and mounted views, respectively, of an exemplary embodiment of a filter back shelf plate of a system for using cloth filters in automated vertical molding.

(5) FIG. 5 illustrates a flowchart of an exemplary embodiment of a method for using cloth filters in automated vertical molding.

(6) FIG. 6 illustrates a perspective view of an exemplary embodiment of a system for using cloth filters in automated vertical molding.

(7) FIG. 7 illustrates a flowchart of an exemplary embodiment of a method for using cloth filters in intricate casting.

TERMS OF ART

(8) As used herein, the term cloth filter means a filter having an interlaced or woven structure.

(9) As used herein, the term side dimension means a length or width of an object.

DETAILED DESCRIPTION OF THE INVENTION

(10) FIGS. 1a-4c and FIG. 6 illustrate exemplary embodiments of a system 100 for using cloth filters 20 in automated vertical molding. System 100 includes an optional filter separation box 10, at least one cloth filter 20, a filter setter 30, a filter print plate 40 and a filter back shelf 50.

(11) FIGS. 1a-1d illustrate perspective, top, front and side views, respectively, of an exemplary embodiment of filter separation box 10 of system 100 for using cloth filters 20 in automated vertical molding. Filter separation box 10 includes a plurality of walls 11a-11d, a base 12 and a plurality of separation structures 13. Walls 11a-11d surround and attach to base 12. Walls 11a-11d are approximately 6 to approximately 12 inches in height. Base 12 forms a square of approximately 12 inches to approximately 18 inches in length and width. Separation structures 13 are integrally formed with base 12, extending along base 12 between walls 11b and 11d, and may number between approximately 4 and approximately 10 depending on the size of the cloth filter 20. Separation structures 13 are approximately 0.5 inches to approximately 0.625 inches wide. The height of each separation structure 13 is no less than one-third the length of cloth filter 20. Separation structures 13 are spaced apart no more than two-thirds the length of cloth filter 20.

(12) In the exemplary embodiment, the cross-section of separation structure 13 is a rounded rectangle. In other embodiments, the cross-section of separation structure 13 may be, but is not limited to, a rectangle, a square, a half-circle or a triangle. In certain embodiments using smaller filters, the cross-section of separation structure 13 may be more rounded shapes such as, but not limited to, an arc. Polygonal angles may be sharp or rounded. Separation structure 13 separates cloth filters 20 when stacked cloth filters 20 drop into filter separation box 10, allowing operators to easily remove a single cloth filter 20.

(13) FIGS. 2a-2d illustrate perspective, top, front and side views, respectively, of an exemplary embodiment of filter setter 30 of system 100 for using cloth filters 20 in automated vertical molding. Filter setter 30 comprises, in part, a housing 31, at least one upper jaw 32 and at least one lower jaw 33. Housing 31 removably mounts to a mechanical arm A. A width of upper jaw 32 is approximately equal to or less than a width of housing 31. A width of lower jaw 33 is approximately equal to or greater than a width of cloth filter 20. In certain embodiments, system 100 includes a plurality of removably attachable upper jaws 32 and a plurality of removably attachable lower jaws 33. This allows upper jaws 32 and lower jaws 33 to be swapped out to accommodate cloth filters 20 having different widths.

(14) Filter setter 30 holds a single cloth filter 20 between upper jaw 32 and lower jaw 33 as mechanical arm A travels to the point of filter insertion into a sand mold M. After cloth filter 20 is inserted into a filter cavity formed by a filter print plate 40, an ejection mechanism discharges cloth filter 20 from filter setter 30, leaving cloth filter 30 in sand mold M. Filter setter 30 is fully described in U.S. patent application Ser. No. 14/610,967 filed Jan. 30, 2015, hereby incorporated by reference in its entirety.

(15) FIGS. 3a-3e illustrate perspective, top, front, side and mounted views, respectively, of an exemplary embodiment of filter print plate 40 of system 100 for using cloth filters 20 in automated vertical molding. Filter print plate 40 mounts to a ram plate R that presses filter print plate 40 into sand mold S to create a cavity into which cloth filter 20 is inserted. Filter print plate 40 creates a cavity high enough to allow an unobstructed insertion of cloth filter 20, but low enough to allow cloth filter 20 to contact the sand during the pouring of molten metal. Foundry plank F at least partially surrounds filter print plate 40 to create an aperture in sand mold M.

(16) Filter print plate 40 has a minimum thickness no less than the thickness of cloth filter 20, and a maximum thickness no greater than twice thickness of cloth filter 20. The side of filter print plate 40 closest to ram plate R is approximately 2-6 mm wider than cloth filter 20. The cavity created by filter print plate 40 is wider than cloth filter 20 to account for insertion of cloth filter 20 into filter setter 30 at oblique angles. Additionally, the cavity created by filter print plate 40 may taper to enable removal of filter print plate 40 without damaging sand mold M. The opening to the cavity may be tapered or chamfered to allow insertion of a warped cloth filter 20.

(17) FIG. 3e shows filter print plate 40 mounted to ram plate R during the founding process. Foundry plank F at least partially surrounds filter print plate 40 to create an aperture in sand mold M.

(18) FIGS. 4a-4c illustrate front, side and mounted views, respectively, of an exemplary embodiment of filter back shelf plate 50 of system 100 for using cloth filters 20 in automated vertical molding. Filter back shelf plate 50 mounts to swing plate S to create a shelf aperture in sand mold M providing additional support for cloth filter 20 after insertion. Filter back shelf plate 50 has a cross-section of an L-shape rotated 90 degrees clockwise.

(19) In the exemplary embodiment, first shelf leg 51 of filter back shelf plate 50 includes a plurality of attachment apertures 52 holding mechanical fasteners that removably mount filter back shelf plate 50 to swing plate S. Second shelf leg 53 has a length ranging from approximately 0.5 inches to approximately 1 inch. Second shelf leg 53 has a width ranging from the side dimension of cloth filter 20 to the side dimension of filter print plate 40. In certain embodiments, attachment apertures 52 are located on second shelf leg 53. In certain embodiments, first shelf leg 51 is longer than second shelf leg 53. In certain embodiments, at least one of first shelf leg 51 or second shelf leg 53 tapers.

(20) FIG. 4c shows filter back shelf plate 50 mounted to swing plate S during the founding process. Foundry plank F at least partially surrounds filter back shelf plate 50 to create an aperture in sand mold M.

(21) FIG. 5 illustrates a flowchart of an exemplary embodiment of a method 500 for using cloth filters 20 in automated vertical molding.

(22) In optional step 502, method 500 deposits a stack of cloth filters 20 into filter separation box 10 to disarrange cloth filters 20 and make them easier to individually remove.

(23) In step 504, method 500 inserts a cloth filter 20 into filter setter 30 mounted to a mechanical arm A.

(24) In step 506, ram plate R with mounted filter print plate 40 compresses sand to create sand mold M. Filter print plate 40 creates at least part of a print aperture in sand mold M, within which three edges of cloth filter 20 rest.

(25) In step 508, swing plate S with mounted filter back shelf 50 compresses sand to create sand mold M. Filter back shelf 50 creates a shelf aperture in sand mold M, within which a fourth edge of cloth filter 20 rests. Method 500 may perform steps 506 and 508 substantially simultaneously.

(26) In step 510, mechanical arm A inserts cloth filter 20 into sand mold M using filter setter 30 until an edge of cloth filter 20 rests in the print aperture. In certain embodiments, an ejection cylinder ejects cloth filter 20 into sand mold M.

(27) In step 512, mechanical arm A removes filter setter 30, leaving cloth filter 20 in sand mold M.

(28) In step 514, swing plate S with a mounted filter back shelf 50 swings up and out of sand mold M.

(29) In step 516, ram plate R with mounted filter print plate 40 pushes sand mold M to a pouring station P, where it abuts another sand mold M. Each sand mold M makes up one half of a casting mold C. Therefore, a single cloth filter 20 will rest in a filter print of a first sand mold M and in a shelf aperture of a second sand mold M.

(30) In step 518, pouring station P pours molten metal into casting mold C through cloth filter 20 to create a cast part.

(31) FIG. 6 illustrates a perspective view of an exemplary embodiment of a system 100 for using cloth filters 20 in automated vertical molding.

(32) FIG. 7 illustrates a flowchart of an exemplary embodiment of a method 700 for using cloth filters 20 in intricate casting.

(33) In optional step 702, method 700 deposits a stack of cloth filters 20 into filter separation box 10 to disarrange cloth filters 20 and make them easier to individually remove.

(34) In step 704, ram plate R with mounted filter print plate 40 compresses sand to create a print aperture between casting mold C and the inlet channel through which molten metal will enter casting mold C. Filter print plate 40 creates at least part of a print aperture in casting mold C, within which three edges of cloth filter 20 rest.

(35) In step 706a, method 700 filter setter 30 inserts cloth filter 20 into the print aperture between casting mold C and the inlet channel.

(36) In certain embodiments, step 706a includes inserting cloth filter 20 into filter setter 30 mounted to a mechanical arm A, then mechanical arm A inserts cloth filter 20 into the print aperture using filter setter 30 until an edge of cloth filter 20 rests in the print aperture, then mechanical arm A removes filter setter 30, leaving cloth filter 20 in the print aperture. In certain embodiments, an ejection cylinder ejects cloth filter 20 into the print aperture.

(37) In alternative step 706b, method 700 manually inserts cloth filter 20 into the print aperture between casting mold C and inlet channel.

(38) Cloth filter 20 will create a barrier that diverts molten metal, creating an area of low-density metal in any metal protrusions that form in the inlet channel, proximal to the casting, as the metal cools and hardens.

(39) In optional step 708, method 700 places a ceramic filter or a second cloth filter in sand mold M. The second cloth filter is placed as described in method 500.

(40) In step 710, ram plate R with mounted filter print plate 40 pushes casting mold C to a pouring station P.

(41) In step 712, pouring station P pours molten metal into casting mold C through cloth filter 20 to create a cast part.

(42) In method 700, cloth filter 20 is positioned at the plane between an inlet metal feed channel and casting mold C before molten metal enters casting mold C. This positioning of cloth filter 20 creates a weak point made of an area of low-density metal called a shear plane in the metal protrusion that forms in the inlet metal feed channel while the cast part cools. Excess metal protrusions with shear planes are easier to remove without damaging the casting. Furthermore, the inlet metal feed channel will not need to have a narrow section proximal to the casting, thus the wide inlet metal feed channel will maintain a high flow rate of molten metal into the cast. In this embodiment, cloth filter 20 is also in position to filter the molten metal as it enters casting mold C and may be used with or without an optional second cloth filter 20 or ceramic filter inserted into sand mold M.

(43) In various embodiments, method 700 measures parameters including time, volume, and pressure to assist in controlling the flow of molten metal into casting mold C.