Full-Automatic Machine for Continuously Forming Horizontal Split Molds in So-Called Non-Pallet and Non-Jacket System

This invention relates to the forming of horizontal split molds in so-called non-pallet and non-jacket systems and, more particularly, to an improved fully automatic machine for continuously forming horizontal split molds.

According to the device of the present invention, raw material sand blown into an upper mold frame and a lower mold frame is squeezed by means of an the upper squeeze plate and an the lower squeeze plate and molded to form a horizontal split mold supported on the lower squeeze plate to be lowered out of the mold frames. When each sand mold is lowered to a position at the level of the upper surface of a teeming platform, it is displace forwardly and shifted onto the teeming platform. Accordingly, neither a pallet nor a jacket is required therefor. Each sand mold thus formed has its forward face bonded to the rear face of the preceding sand mold, and is in a compressed state. Therefore, during the teeming operation, no mold crush and leakage of molten bath occur. The casting operation of the so-called non-pallet, non-jacket and non-weight system can be effected, and the sand molds thus formed and bonded with adjacent ones at their adjacent surfaces are aligned with each other.

Therefore sufficient amounts of said molds can be stored at the narrowest teeming place, so that the teeming operation can be continuously carried out. In this case, at the peripheral part of the lower end of each of the sand molds, bevelled portions are formed to prevent biting of residual sand particles. Small gaps are formed between adjacent square rods of a side teeming platform so that the residual sand particles fall and no sand particles bite in the lower surfaces of the sand molds.

For an understanding of the principles of the invention, reference is made to the following description of a typical embodiment thereof as illustrated in the accompanying drawings.

In the Drawings:

FIG. 1 is a side elevation view of the overall machine embodying the invention;

FIG. 2 is a horizontal plan view illustrating the teeming platform;

FIG. 3 is a plan view of the upper squeeze plate;

FIG. 4 is a front elevation view of the upper squeeze plate as shown in FIG. 3;

FIG. 5 is an enlarged front elevation of the lower mold frame and its support;

FIG. 6 is a partly enlarged elevation view illustrating the raw material sand tank and its connection to the mold frames;

FIG. 7 is an enlarged plan view, illustrating, in more detail, the construction of the laterally extending teeming platform;

FIG. 8 is a side elevation view of a horizontal split sand mold formed with the apparatus of the invention; and

FIG. 9 is a partial front elevation view, looking from the left, of the apparatus as shown in FIG. 1.

In the drawings, at the upper part of stays 2, 2 - - - , planted at the four-corner parts of a bed-plate 1 of the machine body, there is fixed an upper mold fitting frame 4 supporting an upper open mold frame 3. At the lower parts of stays 2, there is supported an open lower mold fitting frame 6, supporting a lower open mold frame 5, and which is displaceable along stays 2, 2 - - - in a vertically slidable manner. At the upper end parts of stays 2, there is mounted an upper stationary frame 7. At the upper surface of upper stationary frame 7, there is mounted a piston-cylinder actuator 9 shifting an upper squeeze plate 8 in a vertical direction whereas, at the lower bedplate 1, there is mounted a piston cylinder actuator 11 shifting a lower squeeze plate 10 in a vertical direction.

Several through holes 12, 12 - - - are formed in upper squeeze plate 8, and a sprue forming rod 13 is fitted in one through hole, while the other unused through holes can be blocked. Furthermore, fitting members or guides 14 are secured to extend from both opposite side surfaces of said lower mold frame 5, and are engaged with and supported slidably along guide rods 15 and 15 arranged on both opposite sides of the lower fitting frame 6. Between mold frames 3 and 5, a match plate 16 is supported by a pair of rear stays 2, and may be engaged with and released from upper mold frame 3. Upper stationary frame 7 also supports a raw material sand tank 17, which is bifurcated at its lower end to form branched pipes 18 and 18. The match plate 16 is inserted laterally between upper mold frame 3 and the lower mold frame 5, and may carry core patterns on its upper surface, lower surface or both surfaces as schematically illustrated in FIGS. 1 and 6. Mold frame support 6 carrying lower mold frame 5 is vertically displaceable along stays 2 by piston-cylinder actuator 6A. At the position in which both upper and lower mold frames are abutted to each other through match plate 16, the upper openings 19 and 20 of branched pipes 18 and 18 and the lower openings 19a and 20a thereof are in sealed engagement with the blow- in ports 21 and 22 at opposite side surfaces of the upper mold frame 3 and blow-in ports 21a and 22a at opposite side surfaces of the lower mold frame 5. After the raw material sand has been blown in from opposite sides of the lower mold frame, the upper squeeze plate 8 is forced downwardly, and the lower squeeze plate 10 is forced upwardly to compress the sand and thereby to form the sand mold. After the sand has been compressed, the upper and lower open mold frames 3 and 5 are separated a distance sufficient to permit match plate 16 to be retracted laterally from between the upper and lower mold frames, together with any core patterns which may be carried by match plate 16. Lower mold frame 5 then is moved to protrude from the side of the lower fitting frame 6, and further, if necessary, a core is inserted therein. Lower mold frame 5 is laterally displaceable along guide rods 15 by a piston-cylinder actuator 5A. The lower mold frame 5 is then restored to the original position, and the upper mold and the lower mold are then directly abutted to each other. The upper and lower sand molds are pushed downward integrally by upper squeeze plate 8, and extruded downwardly from lower mold frame 5 to be pressed onto lower squeeze plate 11, which is then lowered to bring the sand mold into horizontal alignment with a teeming platform 23. Platform 23 is arranged at the front part of the machine frame, and an extruder is provided at the rear part of the machine frame. The extruder then moves the sand mold 24 onto teeming platform 23. The described cycle is then repeated and, as each sand mold is brought into alignment with teeming platform 23, its front surface is bonded to the rear surface of the immediately preceding sand mold on the teeming platform, so that a series of sand molds 24 - - - 24n, bonded together, are supported on forwardly extending teeming platform 23. Furthermore, in this case, the sand molds aligned on said teeming platform 23 are successively compressed by a great force and moved along platform 23. Accordingly, when these sand molds are compressed by a force more than the limit, there ensues a crush or break in the sand mold. Hence, there a predetermined restriction is placed on the number of sand molds aligned on teeming platform 23 and therefore troubles occur in the continuous operation.

Accordingly, in order to promote the working efficiency, side or lateral teeming platform sections 25, in which a large number of square or polygonal rods are aligned parallelly in a direction perpendicularly to the teeming platform 23, are provided so that they are spaced slightly from each other. A predetermined number of sand mold groups 24 aligned on teeming platform 23 are displaced laterally as a unit for transfer onto side teeming platform sections 25, through a compressing plate 26 provided on the opposite of said teeming platform 23. Then, additional sand molds are displaced onto teeming platform 23 and bonded to each other, and compressed. When a predetermined number of sand molds are aligned thereon, these sand molds are further bonded to respective side surfaces of the sand mold group line 24 which has previously been transferred onto side teeming platform section 25, and pressed by member 26 and moved along the platform sections 25.

In such an operation, the front lower end edge and side lower end edges of each sand mold are formed into bevelled portions 27 and 27, thereby to prevent biting of sand particles when the sand molds are transferred. On the front surface of plate 26 there are formed small protruded ridges 31, 31, - - - and, when the sand mold groups are transferred onto lateral teeming platform sections 25, gas vent ridges are formed on the side surface of respective sand molds. Thus, when, on the side teeming platform sections 25, there are aligned sand mold groups 24, 24a, 24b - - - 24n, a ladle car 30 is placed in a freely movable manner on an overhead crane or bridge 29 movable along rails 28, 28 laid on opposite of said teeming platform section 25, thereby to freely teem the aligned sand molds. As previously mentioned, in accordance with the method of the present invention, even when sand molds of complicated shape are formed, the raw material sand is blown in from opposite sides of the upper mold frame and lower mold frame. Therefore, despite the presence of a match plate between the upper mold and the lower mold, no shaped part is produced, the molds are filled with sand uniformly even at corners, and squeezed sand molds, having a uniform density and hardness at any part, are obtained, and hence, neither pallet nor jacket is required therefor. Also, in the teeming operation, since sand molds are bonded to each other at their side surfaces while compressed and aligned, there is no possibility that mold crush or leakage of the molten bath may occur. Since the upper squeeze plate is so formed that the sprue forming rod 13 can be fitted at a predetermined position thereon, a sprue can be formed in the sane blow-in process and squeezing process. In the case where it is necessary to insert the core in the machine after the match plate is pulled back, the lower mold frame is caused to slide to protude from the side of the machine body, whereby the core may be inserted accurately and quickly. Furthermore, in the front part of the machine body, a teeming platform 23 is provided and the side teeming platform sections 25 are provided one of said teeming platform, 23. The sand molds aligned on the teeming platform 23 are transferred onto the side teeming platform sections 25 through the compressing plate 26. Respective sand molds are bonded to the side surfaces of the adjacent sand molds and aligned, and hence it is possible to store a great number of sand molds in a minimum space, the teeming ladle car can be transferred on the overhead bridge or crane running on the rails 28, thereby to carry out the teeming operation. Accordingly, the operations from the forming of sand molds to the teeming can be automatically carried out, whereby the operational efficiency can be improved.