U.S. patent application number 14/783185 was filed with the patent office on 2016-02-18 for pulling-up-type continuous casting apparatus and upward continuous casting method.
This patent application is currently assigned to TOYOTA JIDOSHA KABUSHIKI KAISHA. The applicant listed for this patent is Yusei KUSAKA. Invention is credited to Yusei KUSAKA.
Application Number | 20160045954 14/783185 |
Document ID | / |
Family ID | 51689038 |
Filed Date | 2016-02-18 |
United States Patent
Application |
20160045954 |
Kind Code |
A1 |
KUSAKA; Yusei |
February 18, 2016 |
PULLING-UP-TYPE CONTINUOUS CASTING APPARATUS AND UPWARD CONTINUOUS
CASTING METHOD
Abstract
A pulling-up-type continuous casting apparatus according to the
present invention includes a holding furnace, a draw-out part, a
shape-defining member, and a temperature measurement unit. The
holding furnace holds a molten metal. The draw-out part draws out
the molten metal from a molten-metal surface of the molten metal
that is held in the holding furnace. The shape-defining member
defines a cross-sectional shape of a cast-metal article to be cast
by applying an external force to a held molten metal which is an
unsolidified molten metal that has been drawn out by the draw-out
part, the shape-defining member being located in the vicinity of
the molten-metal surface. The temperature measurement unit measures
the temperature of the held molten metal, and the temperature of
the held molten metal is controlled based on the result of
measurement in the temperature measurement unit.
Inventors: |
KUSAKA; Yusei; (Toyota-shi,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KUSAKA; Yusei |
Aichi |
|
JP |
|
|
Assignee: |
TOYOTA JIDOSHA KABUSHIKI
KAISHA
Toyota-shi, Aichi
JP
|
Family ID: |
51689038 |
Appl. No.: |
14/783185 |
Filed: |
April 10, 2013 |
PCT Filed: |
April 10, 2013 |
PCT NO: |
PCT/JP2013/002456 |
371 Date: |
October 8, 2015 |
Current U.S.
Class: |
164/452 ;
164/154.7 |
Current CPC
Class: |
B22D 11/16 20130101;
B22D 11/01 20130101; B22D 11/145 20130101; B22D 11/08 20130101;
B22D 11/1246 20130101 |
International
Class: |
B22D 11/16 20060101
B22D011/16; B22D 11/14 20060101 B22D011/14; B22D 11/01 20060101
B22D011/01 |
Claims
1. A pulling-up-type continuous casting apparatus, comprising: a
holding furnace that holds a molten metal; a draw-out part that
draws out the molten metal from a molten-metal surface of the
molten metal that is held in the holding furnace; a shape-defining
member that defines a cross-sectional shape of a cast-metal article
to be cast by applying an external force to a held molten metal
which is an unsolidified molten metal that has been drawn out by
the draw-out part, the shape-defining member being located in the
vicinity of the molten-metal surface; and a temperature measurement
unit that measures the temperature of the held molten metal,
wherein the temperature of the held molten metal is controlled
based on the result of measurement in the temperature measurement
unit.
2. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the temperature measurement unit is a thermocouple
and a temperature measuring junction of the temperature measurement
unit is provided in the held molten metal.
3. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the temperature measurement unit is a thermocouple
and a temperature measuring junction of the temperature measurement
unit is provided in the molten metal in the vicinity of the held
molten metal.
4. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the temperature measurement unit is a thermocouple
and a temperature measuring junction of the temperature measurement
unit is provided in the molten metal immediately below the held
molten metal.
5. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the temperature measurement unit is a thermocouple
and a temperature measuring junction of the temperature measurement
unit is provided in the vicinity of a contact surface between the
shape-defining member and the held molten metal inside the
shape-defining member.
6. The pulling-up-type continuous casting apparatus according to
claim 1, wherein the holding furnace controls the temperature of
the molten metal based on the result of measurement in the
temperature measurement unit to control the temperature of the held
molten metal.
7. The pulling-up-type continuous casting apparatus according to
claim 1, further comprising a temperature controller that controls
the temperature of the held molten metal based on the result of
measurement in the temperature measurement unit.
8. The pulling-up-type continuous casting apparatus according to
claim 7, wherein the temperature controller is provided in the
molten metal in the vicinity of the held molten metal.
9. The pulling-up-type continuous casting apparatus according to
claim 7, wherein the temperature controller is provided in the
molten metal immediately below the held molten metal.
10. The pulling-up-type continuous casting apparatus according to
claim 7, wherein the temperature controller is formed to surround
the molten metal in the vicinity of the held molten metal.
11. The pulling-up-type continuous casting apparatus according to
claim 7, further comprising a separating part that surrounds the
molten metal in the vicinity of the held molten metal.
12. The pulling-up-type continuous casting apparatus according to
claim 7, wherein the temperature controller includes a protruding
part that extends to the inside of the held molten metal.
13. The pulling-up-type continuous casting apparatus according to
claim 7, wherein the temperature controller is provided in the
vicinity of a contact surface between the shape-defining member and
the held molten metal inside the shape-defining member.
14. A pulling-up-type continuous casting method comprising the
steps of: placing a shape-defining member that defines a
cross-sectional shape of a cast-metal article to be cast in the
vicinity of a molten-metal surface of a molten metal that is held
in a holding furnace; pulling up the molten metal through the
shape-defining member; and measuring the temperature of a held
molten metal which is an unsolidified molten metal that has been
pulled up; and controlling the temperature of the held molten metal
based on the result of the measurement.
15-26. (canceled)
Description
TECHNICAL FIELD
[0001] The present invention relates to a pulling-up-type
continuous casting apparatus and a pulling-up-type continuous
casting method.
BACKGROUND ART
[0002] In Patent Literature 1, a free casting method is proposed by
the present inventors as an epoch-making continuous casting method
that does not require a mold. As shown in Patent Literature 1, when
a starter is pulled up after it is immersed into the surface of a
melted metal (molten metal) (in other words, the molten-metal
surface), the molten metal is also drawn out following the starter
by the surface film or surface tension of the molten metal. Here,
by drawing out the molten metal through a shape-defining member
that is located in the vicinity of the molten-metal surface and
cooling the molten metal, a cast-metal article with a desired
cross-sectional shape can be cast continuously.
[0003] In an ordinary continuous casting method, not only the
cross-sectional shape but also the longitudinal shape is defined by
a mold. In particular, the cast-metal article that is produced by a
continuous casting method has a shape that is linearly elongated in
its longitudinal direction because the solidified metal (in other
words, the cast-metal article) must be passed through a mold.
[0004] In contrast, a shape-defining member that is used in a free
casting method defines only the cross-sectional shape of the
cast-metal article and does not define the longitudinal shape of
the cast-metal article. In addition, because the shape-defining
member is movable in directions parallel to the molten-metal
surface (in other words, horizontal directions), cast-metal
articles with different longitudinal shapes can be obtained. For
example, a hollow cast-metal article (in other words, a pipe) that
is formed to have a zigzag or spiral, not linear, configuration
along its length is disclosed in Patent Literature 1.
CITATION LIST
Patent Literature
[Patent Literature 1] Japanese Unexamined Patent Application
Publication No. 2012-61518
SUMMARY OF INVENTION
Technical Problem
[0005] The present inventors have found the following problem.
[0006] According to the free casting method disclosed in Patent
Literature 1, it is impossible to accurately control the
temperature of the unsolidified molten metal that has been pulled
up from the molten-metal surface following the starter (held molten
metal). Thus, according to the free casting method disclosed in
Patent Literature 1, it is impossible to accurately control the
speed at which the starter is pulled up.
[0007] The present invention has been made in view of the above
circumstances and aims to provide a pulling-up-type continuous
casting apparatus and a pulling-up-type continuous casting method
in which the speed at which the starter is pulled up can be
accurately controlled by accurately controlling the temperature of
the held molten metal.
Solution to Problem
[0008] A pulling-up-type continuous casting apparatus according to
one aspect of the present invention includes: a holding furnace
that holds a molten metal; a draw-out part that draws out the
molten metal from a molten-metal surface of the molten metal that
is held in the holding furnace; a shape-defining member that
defines a cross-sectional shape of a cast-metal article to be cast
by applying an external force to a held molten metal which is an
unsolidified molten metal that has been drawn out by the draw-out
part, the shape-defining member being located in the vicinity of
the molten-metal surface; and a temperature measurement unit that
measures the temperature of the held molten metal, in which the
temperature of the held molten metal is controlled based on the
result of measurement in the temperature measurement unit.
According to this structure, the temperature of the held molten
metal can be accurately controlled, whereby it is possible to
accurately control the speed at which the starter is pulled up.
[0009] It is preferable that the temperature measurement unit be a
thermocouple and a temperature measuring junction of the
temperature measurement unit be provided in the held molten
metal.
[0010] It is preferable that the temperature measurement unit be a
thermocouple and a temperature measuring junction of the
temperature measurement unit be provided in the molten metal in the
vicinity of the held molten metal.
[0011] It is preferable that the temperature measurement unit be a
thermocouple and a temperature measuring junction of the
temperature measurement unit be provided in the molten metal
immediately below the held molten metal.
[0012] It is preferable that the temperature measurement unit be a
thermocouple and a temperature measuring junction of the
temperature measurement unit be provided in the vicinity of a
contact surface between the shape-defining member and the held
molten metal inside the shape-defining member.
[0013] It is preferable that the holding furnace control the
temperature of the molten metal based on the result of measurement
in the temperature measurement unit to control the temperature of
the held molten metal.
[0014] It is preferable that the pulling-up-type continuous casting
apparatus further include a temperature controller that controls
the temperature of the held molten metal based on the result of
measurement in the temperature measurement unit.
[0015] It is preferable that the temperature controller be provided
in the molten metal in the vicinity of the held molten metal.
[0016] It is preferable that the temperature controller be provided
in the molten metal immediately below the held molten metal.
[0017] It is preferable that the temperature controller be formed
to surround the molten metal in the vicinity of the held molten
metal.
[0018] It is preferable that the pulling-up-type continuous casting
apparatus further include a separating part that surrounds the
molten metal in the vicinity of the held molten metal.
[0019] It is preferable that the temperature controller include a
protruding part that extends to the inside of the held molten
metal.
[0020] It is preferable that the temperature controller be provided
in the vicinity of a contact surface between the shape-defining
member and the held molten metal inside the shape-defining
member.
[0021] A pulling-up-type continuous casting method according to one
aspect of the present invention includes the steps of: placing a
shape-defining member that defines a cross-sectional shape of a
cast-metal article to be cast in the vicinity of a molten-metal
surface of a molten metal that is held in a holding furnace;
pulling up the molten metal through the shape-defining member; and
measuring the temperature of a held molten metal which is an
unsolidified molten metal that has been pulled up; and controlling
the temperature of the held molten metal based on the result of the
measurement. According to this structure, the temperature of the
held molten metal can be accurately controlled, whereby it is
possible to accurately control the speed at which the starter is
pulled up.
[0022] It is preferable that the pulling-up-type continuous casting
method include providing a temperature measuring junction of a
thermocouple in the held molten metal to measure the temperature of
the held molten metal.
[0023] It is preferable that the pulling-up-type continuous casting
method include providing a temperature measuring junction of a
thermocouple in the molten metal in the vicinity of the held molten
metal to measure the temperature of the held molten metal.
[0024] It is preferable that the pulling-up-type continuous casting
method include providing a temperature measuring junction of a
thermocouple in the molten metal immediately below the held molten
metal to measure the temperature of the held molten metal.
[0025] It is preferable that the pulling-up-type continuous casting
method include providing a temperature measuring junction of a
thermocouple in the vicinity of a contact surface between the
shape-defining member and the held molten metal inside the
shape-defining member to measure the temperature of the held molten
metal.
[0026] It is preferable that the pulling-up-type continuous casting
method include controlling the temperature of the molten metal by
the holding furnace to control the temperature of the held molten
metal.
[0027] It is preferable that the temperature of the held molten
metal be controlled by a temperature controller.
[0028] It is preferable that the temperature controller be provided
in the molten metal in the vicinity of the held molten metal.
[0029] It is preferable that the temperature controller be provided
in the molten metal immediately below the held molten metal.
[0030] It is preferable that the temperature controller be formed
to surround the molten metal in the vicinity of the held molten
metal.
[0031] It is preferable that a separating part that surrounds the
molten metal in the vicinity of the held molten metal be further
provided.
[0032] It is preferable that a protruding part extending to the
inside of the held molten metal be provided in the temperature
controller.
[0033] It is preferable that the temperature controller be provided
in the vicinity of a contact surface between the shape-defining
member and the held molten metal in the shape-defining member.
Advantageous Effects of Invention
[0034] According to the present invention, it is possible to
provide a pulling-up-type continuous casting apparatus and a
pulling-up-type continuous casting method in which the speed at
which the starter is pulled up can be accurately controlled by
accurately controlling the temperature of the held molten
metal.
BRIEF DESCRIPTION OF DRAWINGS
[0035] FIG. 1 is a cross-sectional view showing a configuration
example of a free casting apparatus according to a first
embodiment;
[0036] FIG. 2 is a plan view of an internal shape-defining member
102a and an external shape-defining member 102b;
[0037] FIG. 3 is a cross-sectional view showing a modified example
of the free casting apparatus according to the first
embodiment;
[0038] FIG. 4 is a cross-sectional view showing a configuration
example of a free casting apparatus according to a second
embodiment;
[0039] FIG. 5 is a cross-sectional view of a modified example of
the free casting apparatus according to the second embodiment;
[0040] FIG. 6 is a cross-sectional view showing a first specific
configuration example of a temperature controller 109;
[0041] FIG. 7 is a cross-sectional view showing a second specific
configuration example of the temperature controller 109;
[0042] FIG. 8 is a cross-sectional view showing another
configuration example of the free casting apparatus according to
the present invention;
[0043] FIG. 9 is a cross-sectional view showing another
configuration example of the free casting apparatus according to
the present invention;
[0044] FIG. 10 is a cross-sectional view showing another
configuration example of the free casting apparatus according to
the present invention; and
[0045] FIG. 11 is a cross-sectional view showing a modified example
of the free casting apparatus according to the present
invention.
DESCRIPTION OF EMBODIMENTS
[0046] Description is hereinafter made of specific embodiments to
which the present invention is applied with reference to the
drawings. It should be noted that the present invention is not
limited to the following embodiments. The following description and
the drawings are simplified as needed to clarify the
description.
First Embodiment
[0047] First, with reference to FIG. 1, a free casting apparatus
(pulling-up-type continuous casting apparatus) according to a first
embodiment will be described. FIG. 1 is a cross-sectional view
showing a configuration example of the free casting apparatus
according to the first embodiment. As shown in FIG. 1, the free
casting apparatus according to the first embodiment includes a
molten metal holding furnace (holding furnace) 101, an internal
shape-defining member 102a, an external shape-defining member 102b,
supporting rods 103 and 104, an actuator 105, a cooling gas nozzle
106, a draw-out part 107, and a thermocouple (temperature
measurement unit) 108.
[0048] The molten metal holding furnace 101 holds a molten metal M1
of aluminum or an aluminum alloy, for example, and maintains the
molten metal M1 at a prescribed temperature. In particular, in this
embodiment, a case in which the molten metal holding furnace 101
holds the molten metal M1 at a temperature according to a result of
measurement in the thermocouple 108 will be described as an example
(described later). In the example that is shown in FIG. 1, the
surface level of the molten metal M1 (in other words, the
molten-metal surface) is lowered as the casting proceeds because
the molten metal holding furnace 101 is not replenished with molten
metal during casting. However, a configuration in which the molten
metal holding furnace 101 is replenished with molten metal during
casting to maintain the molten-metal surface level constant is also
possible. It should be appreciated that the molten metal M1 may be
a melt of a metal other than aluminum or an alloy thereof.
[0049] The internal shape-defining member 102a and the external
shape-defining member 102b are made of ceramic or stainless steel,
for example, and are located in the vicinity of the molten-metal
surface. In the example shown in FIG. 1, the internal
shape-defining member 102a and the external shape-defining member
102b are placed to contact the molten-metal surface. However, the
internal shape-defining member 102a and the external shape-defining
member 102b may be located with the principal surface thereof on
its lower side (on the side that faces the molten-metal surface)
away from the molten-metal surface. Specifically, a prescribed
(approximately 0.5 mm, for example) gap may be provided between the
principal surface of the internal shape-defining member 102a and
the external shape-defining member 102b on its lower side and the
molten-metal surface.
[0050] The internal shape-defining member 102a defines the internal
shape of a cast metal M3 (or a cast-metal article M3) to be cast
and the external shape-defining member 102b defines the external
shape of the cast metal M3 to be cast. The cast metal M3 shown in
FIG. 1 is a hollow cast-metal article that has a tubular shape
(that is, a pipe) in a horizontal cross-section (which is
hereinafter referred to as "transverse cross-section"). More
specifically, the internal shape-defining member 102a defines the
internal shape of the transverse cross-section of the cast metal M3
and the external shape-defining member 102b defines the external
shape of the transverse cross-section of the cast metal M3.
[0051] FIG. 2 is a plan view of the internal shape-defining member
102a and the external shape-defining member 102b. The
cross-sectional view of the internal shape-defining member 102a and
the external shape-defining member 102b shown in FIG. 1 corresponds
to a cross-sectional view that is taken along the line I-I in FIG.
2. As shown in FIG. 2, the external shape-defining member 102b has
a rectangular planar shape, for example, and has a circular opening
at its center. The internal shape-defining member 102a has a
circular planar shape and is located at the center of the opening
of the external shape-defining member 102b. The gap between the
internal shape-defining member 102a and the external shape-defining
member 102b is a molten metal passing part 102c through which the
molten metal is passed. As described above, a shape-defining member
102 is constituted of the internal shape-defining member 102a, the
external shape-defining member 102b, and the molten metal passing
part 102c.
[0052] The draw-out part 107 includes a starter (draw-out member)
ST that is immersed into the molten metal M1, and a lifter PL (not
shown) that drives the starter ST in, for example, vertical
directions.
[0053] As shown in FIG. 1, the molten metal M1 is joined to the
starter ST that is immersed thereinto and then pulled up through
the molten metal passing part 102c following the starter ST with
its contour held by the surface film or surface tension thereof The
molten metal that is pulled up from the molten-metal surface
following the starter ST (or the cast metal M3 that is formed by
solidification of the molten metal M1 that has been drawn out by
the starter ST) by the surface film or surface tension of the
molten metal M1 is herein referred to as "held molten metal M2".
The interface between the cast metal M3 and the held molten metal
M2 is a solidification interface.
[0054] The starter ST is made of ceramic or stainless steel, for
example. The surfaces of the starter ST may be covered with a
protective coating (not shown), such as that of a salt crystal. In
this case, because melt-bonding between the starter ST and the
molten metal M1 can be prevented, the releasability between the
starter ST and the cast metal M3 can be improved. This makes it
possible to reuse the starter ST. In addition, the starter ST may
have irregular surfaces. In this case, because the protective
coating can be easily deposited (precipitated) on the surfaces of
the starter ST, the releasability between the starter ST and the
cast metal M3 can be further improved. At the same time, the
binding force in the pull-up direction between the starter ST and
the molten metal M1 during the draw-out of the molten metal can be
improved.
[0055] The supporting rod 103 supports the internal shape-defining
member 102a and the supporting rod 104 supports the external
shape-defining member 102b. The positional relation between the
internal shape-defining member 102a and the external shape-defining
member 102b can be maintained by the supporting rods 103 and 104.
By forming the supporting rod 103 having a pipe structure, causing
cooling gas to flow through the supporting rod 103, and further
providing a blow-out hole in the internal shape-defining member
102a, the cast metal M3 can be cooled from inside as well.
[0056] Both the supporting rods 103 and 104 are coupled to the
actuator 105. The actuator 105 allows the supporting rods 103 and
104 to move up and down (in vertical directions) and in horizontal
directions while keeping the positional relation between the
internal shape-defining member 102a and the external shape-defining
member 102b. According to this structure, the actuator 105 can move
the internal shape-defining member 102a and the external
shape-defining member 102b downward when the molten-metal surface
level is lowered as the casting proceeds. In addition, because the
actuator 105 can move the internal shape-defining member 102a and
the external shape-defining member 102b in horizontal directions,
the longitudinal shape of the cast metal M3 can be changed
freely.
[0057] The cooling gas nozzle (cooling part) 106 is used to blow
cooling gas (e.g., air, nitrogen, argon) onto the starter ST and
the cast metal M3 to cool the starter ST and the cast metal M3. By
cooling the starter ST and the cast metal M3 with the cooling gas
while the cast metal M3 is being pulled up by the lifter PL (not
shown) that has been coupled to the starter ST, the held molten
metal M2 in the vicinity of the solidification interface is
sequentially solidified and the cast metal M3 is formed
continuously.
[0058] The thermocouple 108 is used to measure the temperature of
the held molten metal M2. In the example shown in FIG. 1, a
temperature measuring junction of the thermocouple is provided
inside of the held molten metal M2. According to this structure,
the thermocouple 108 is able to accurately measure the temperature
of the held molten metal M2. The position where the temperature
measuring junction of the thermocouple 108 is provided is not
limited to the inside of the held molten metal M2 and the
temperature measuring junction of the thermocouple 108 may be
provided in the molten metal M1 which is in the vicinity of the
held molten metal M2 or is immediately below the held molten metal
M2, as shown in FIG. 3. Further, temperature measuring means other
than the thermocouple 108 may be used as long as the temperature
measuring means is able to measure the temperature of the held
molten metal M2.
[0059] The molten metal holding furnace 101 controls the
temperature of the molten metal M1 based on the result of
measurement in the thermocouple 108 as described above. According
to this structure, the temperature of the held molten metal M2 is
accurately controlled. As a result, for example, the temperature of
the held molten metal M2 can be reduced to about a melting point,
whereby it is possible to improve the speed at which the starter ST
is pulled up (that is, to accurately control the speed at which the
starter ST is pulled up).
[0060] Next, with reference to FIG. 1, a free casting method
according to this embodiment will be described.
[0061] First, the starter ST is moved downward and immersed into
the molten metal M1 through the molten metal passing part 102c
which is between the internal shape-defining member 102a and the
external shape-defining member 102b.
[0062] Then, the starter ST starts to be pulled up at a prescribed
speed. Here, even after the starter ST is separated from the
molten-metal surface, the molten metal M1 is pulled up (drawn out)
from the molten-metal surface following the starter ST by the
surface film or surface tension thereof and forms a held molten
metal M2. As shown in FIG. 1, the held molten metal M2 is formed in
the molten metal passing part 102c which is between the internal
shape-defining member 102a and the external shape-defining member
102b. In other words, a shape is imparted to the held molten metal
M2 by the internal shape-defining member 102a and the external
shape-defining member 102b.
[0063] Next, the starter ST (and the cast metal M3) are cooled by
the cooling gas blown out of the cooling gas nozzle 106. As a
result, the held molten metal M2 is sequentially solidified from
top to bottom and the cast metal M3 grows. In this way, the cast
metal M3 can be cast continuously.
[0064] While casting is being carried out, the thermocouple 108
measures the temperature of the held molten metal M2. The molten
metal holding furnace 101 controls the temperature of the molten
metal M1 based on the result of measurement in the thermocouple
108. According to this structure, the temperature of the held
molten metal M2 is accurately controlled. As a result, for example,
the temperature of the held molten metal M2 can be lowered to about
the melting point, whereby it is possible to improve the speed at
which the starter ST is pulled up (that is, to accurately control
the speed at which the starter ST is pulled up).
[0065] As described above, the free casting apparatus according to
this embodiment includes the thermocouple 108 that measures the
temperature of the held molten metal M2 and accurately controls the
temperature of the held molten metal M2 based on the result of
measurement in the thermocouple 108. According to this structure,
the free casting apparatus according to this embodiment is able to
lower the temperature of the held molten metal M2 to about the
melting point, whereby it is possible to improve the speed at which
the starter ST is pulled up (that is, to accurately control the
speed at which the starter ST is pulled up).
[0066] While the case in which the temperature of the held molten
metal M2 is constantly measured while the casting is being carried
out has been described in the above embodiment, the present
invention is not limited to this case. The temperature of the held
molten metal M2 may not be measured, for example, after the speed
at which the starter ST is pulled up is determined. Accordingly,
for example, the temperature measuring junction of the thermocouple
108 may be provided inside the held molten metal M2 or in the
vicinity of the held molten metal M2 with the start of the casting
and may be removed after the speed at which the starter ST is
pulled up is determined.
Second Embodiment
[0067] FIG. 4 is a cross-sectional view showing a configuration
example of a free casting apparatus according to a second
embodiment. In the free casting apparatus shown in FIG. 1 stated
above, the molten metal holding furnace 101 controls the
temperature of the held molten metal M2 by controlling the
temperature of the molten metal M1 based on the result of
measurement in the thermocouple 108. Meanwhile, the free casting
apparatus shown in FIG. 4 further includes a temperature controller
109 that controls the temperature of the held molten metal M2 (or
the molten metal M1 in the vicinity of the held molten metal M2)
based on the result of measurement in the thermocouple 108.
[0068] The temperature controller 109 is provided in the molten
metal M1 which is in the vicinity of the held molten metal M2 or is
immediately below the held molten metal M2 and controls the
temperature of the molten metal M1 which is in the vicinity of the
held molten metal M2 or is immediately below the held molten metal
M2 based on the result of measurement in the thermocouple 108. For
example, the temperature controller 109 heats the molten metal M1
by a heater or the like or cools the molten metal M1 by causing
refrigerant to flow through a refrigerant circuit. According to
this structure, it is possible to control the temperature of the
held molten metal M2 with higher accuracy.
[0069] Since the other structures of the free casting apparatus
shown in FIG. 4 is similar to those of the free casting apparatus
shown in FIG. 1, the description thereof will be omitted. Note that
the position where the temperature measuring junction of the
thermocouple 108 is provided is not limited to the inside of the
held molten metal M2 and the temperature measuring junction of the
thermocouple 108 may be provided in the molten metal M1 which is in
the vicinity of the held molten metal M2 or is immediately below
the held molten metal M2, as shown in FIG. 5.
(First Specific Configuration Example of Temperature Controller
109)
[0070] FIG. 6 is a cross-sectional view showing a first specific
configuration example of the temperature controller 109. In the
example shown in FIG. 6, the temperature controller 109 is formed
to surround the molten metal M1 which is in the vicinity of the
held molten metal M2 or is immediately below the held molten metal
M2.
[0071] More specifically, in the example shown in FIG. 6, the
temperature controller 109 is constituted of a main body part and
protruding parts. The main body part of the temperature controller
109 is provided immediately below the held molten metal M2. The
protruding parts of the temperature controller 109 are provided to
protrude upwardly from both ends of the main body part so as to
separate the molten metal M1 which is in the vicinity of the held
molten metal M2 or is immediately below the held molten metal M2
from the other area of the molten metal M1. However, the molten
metal M1 which is in the vicinity of the held molten metal M2 or is
immediately below the held molten metal M2 and the other area of
the molten metal M1 are not completely separated from each
other.
[0072] According to this structure, the temperature of the held
molten metal M2 can be controlled with further accuracy.
(Second Specific Configuration Example of Temperature Controller
109)
[0073] FIG. 7 is a cross-sectional view showing a second specific
configuration example of the temperature controller 109. In the
example shown in FIG. 7, the temperature controller 109 is formed
to surround the molten metal M1 which is in the vicinity of the
held molten metal M2 or is immediately below the held molten metal
M2 and includes a protruding part extending to the inside of the
held molten metal M2.
[0074] More specifically, in the example shown in FIG. 7, the
temperature controller 109 is constituted of a main body part, a
first protruding part, and a second protruding part. The main body
part of the temperature controller 109 is provided immediately
below the held molten metal M2. The first protruding part of the
temperature controller 109 is provided to protrude upwardly from
both ends of the main body part so as to separate the molten metal
M1 which is in the vicinity of the held molten metal M2 or is
immediately below the held molten metal M2 from the other area of
the molten metal M1. However, the molten metal M1 which is in the
vicinity of the held molten metal M2 or is immediately below the
held molten metal M2 and the other area of the molten metal M1 are
not completely separated from each other. Further, the second
protruding part of the temperature controller 109 is provided to
protrude upwardly from the central part of the upper surface of the
main body part. This second protruding part extends to the inside
of the held molten metal M2.
[0075] According to the above structure, it is possible to directly
control the temperature of the held molten metal M2 (to control the
temperature of the held molten metal M2 further accurately).
[0076] As described above, the free casting apparatus according to
this embodiment includes the thermocouple 108 that measures the
temperature of the held molten metal M2 and the temperature
controller 109 that controls the temperature of the held molten
metal M2 based on the result of measurement in the thermocouple
108. Accordingly, the free casting apparatus according to this
embodiment is able to control the temperature of the held molten
metal M2 further accurately, whereby it is possible to further
improve the speed at which the starter ST is pulled up (that is, to
control the speed at which the starter ST is pulled up further
accurately).
Third Embodiment
[0077] In this embodiment, another configuration example of the
free casting apparatus according to the present invention will be
described.
(Another Configuration Example of Free Casting Apparatus According
to Present Invention (Case 1))
[0078] FIG. 8 is a cross-sectional view showing another
configuration example of the free casting apparatus according to
the present invention. In the free casting apparatus shown in FIG.
8, the temperature measuring junction of the thermocouple 108 is
provided in the vicinity of the contact surface between the
shape-defining member 102 and the held molten metal M2 inside the
shape-defining member 102 (in the example shown in FIG. 8, external
shape-defining member 102b). Since the other structures of the free
casting apparatus shown in FIG. 8 are similar as those of the free
casting apparatus shown in FIG. 4, the description thereof will be
omitted.
(Another Configuration Example of Free Casting Apparatus According
to Present Invention (Case 2))
[0079] FIG. 9 is a cross-sectional view showing another
configuration example of the free casting apparatus according to
the present invention. In the free casting apparatus shown in FIG.
9, the temperature controller 109 is provided in the vicinity of
the contact surface between the shape-defining member 102 and the
held molten metal M2 inside the shape-defining member 102. In other
words, in the free casting apparatus shown in FIG. 9, a function of
the temperature controller 109 is added to the shape-defining
member 102. Since the other structures of the free casting
apparatus shown in FIG. 9 are similar to those of the free casting
apparatus shown in FIG. 4, the descriptions thereof will be
omitted.
(Another Configuration Example of Free Casting Apparatus According
to Present Invention (Case 3))
[0080] FIG. 10 is a cross-sectional view showing another
configuration example of the free casting apparatus according to
the present invention. In the free casting apparatus shown in FIG.
10, besides the temperature controller 109, a separating part 110
formed to surround the molten metal M1 which is in the vicinity of
the held molten metal M2 or is immediately below the held molten
metal M2 is further provided. Since the other structures of the
free casting apparatus shown in FIG. 10 are similar to those of the
free casting apparatus shown in FIG. 4, the descriptions thereof
will be omitted.
[0081] As described above, the free casting apparatus according to
the first to third embodiments above includes the thermocouple 108
that measures the temperature of the held molten metal M2 and the
temperature controller 109 (or the molten metal holding furnace
101) that controls the temperature of the held molten metal M2
based on the result of measurement in the thermocouple 108.
Accordingly, the free casting apparatus according to the first to
third embodiments is able to accurately control the temperature of
the held molten metal M2, whereby it is possible to improve the
speed at which the starter ST is pulled up (that is, to accurately
control the speed at which the starter ST is pulled up).
[0082] While the case in which the cast-metal article having a
cylindrical shape (hollow cast-metal article) is formed has been
described as an example in the above embodiments, the present
invention is not limited thereto. The present invention is also
applicable to a case in which a cast-metal article with a shape of
a circular column is formed as shown in FIG. 11 or cases in which
cast-metal articles having other shapes are formed.
[0083] Note that the present invention is not limited to the above
embodiments and may be changed as needed without departing from its
scope. For example, the above-mentioned configuration examples may
be used in combination.
REFERENCE SIGNS LIST
[0084] 101 Molten Metal Holding Furnace [0085] 102 Shape-Defining
Member [0086] 102a Internal Shape-Defining Member [0087] 102b
External Shape-Defining Member [0088] 102c Molten Metal Passing
Part [0089] 103, 104 Supporting Rod [0090] 105 Actuator [0091] 106
Cooling Gas Nozzle [0092] 107 Draw-Out Part [0093] 108 Thermocouple
[0094] 109 Temperature Controller [0095] 110 Separating Part [0096]
M1 Molten Metal [0097] M2 Held Molten Metal [0098] M3 Cast Metal
[0099] ST Starter [0100] PL Lifter
* * * * *