Description:FIELD OF THE INVENTION

[0001] The present invention relates to a vertical centrifugal casting device that is capable of automating centrifugal casting process, ensuring precise control and reducing human error as well as efficiently measures and dispenses material, minimizing waste and reducing production time, thereby ensures uniform heating, melting, and cooling of material, producing high-quality castings with consistent properties.

BACKGROUND OF THE INVENTION

[0002] Centrifugal casting is a widely used manufacturing process for producing castings with high precision and accuracy. However, traditional methods of centrifugal casting have several limitations and drawbacks that hinder their efficiency and effectiveness. With the increasing demand for complex castings with high accuracy and precision, there is a need for a more advanced and efficient centrifugal casting process.

[0003] Traditional centrifugal casting methods involve manually measuring and dispensing metallic flakes into a melting container, which is then heated to melt the flakes. The molten metal is then poured into a mold, which is rotated to achieve centrifugal force. However, these methods are time-consuming, labor-intensive, and prone to human error. Moreover, the manual process of measuring and dispensing metallic flakes can lead to inconsistent material properties and castings with defects.

[0004] KR20110026175A discloses a vertical centrifugal casting method using a hollow core, for increasing productivity than the producing method using forging or welding, is provided to simultaneously form finished products in standard size by using a large size gear and flange. A vertical centrifugal casting method using a hollow core comprises follows. A core is partitioned into a lower core and an upper core. The upper and lower cores are made of molding sands. The upper and lower core is fixed to the center area of upper and lower molds of a vertical centrifugal casting mold, respectively. The inside of the upper core is formed in cavity. Molten metal is inserted through a hollow. The upper and lower cores are separated in a vertical direction. The molten metal charged in the hollow of the upper core is filled in the inside of the mold through a space between cores.

[0005] CN202779678U discloses the utility model provides a centrifugal casting machine which comprises a motor, a main shaft, an operation platform and a clamping fixture. The main shaft is installed movably on at least two bearing seats through bearings. One end of the main shaft is provided fixedly with the operation platform. The other end of the main shaft is provided with a belt wheel. One end of the motor is further provided with a belt wheel. The belt wheel arranged on the motor and the belt wheel arranged on the main shaft are driven through a triangle belt. One side of the clamping fixture is fixed with the operation platform through bolts. The other side of the clamping fixture is fixed with a covering plate through bolts. The covering plate is in a round ring shape. The external diameter of the covering plate is equal to the external diameter of the clamping fixture. The inner diameter of the covering plate is smaller than the inner diameter of the clamping fixture. The centrifugal casting machine has the advantages of being simple in structure, convenient to operate, good in usability, capable of satisfying process requirement of the production technology, reducing production cost and reducing energy consumption greatly, and the like

[0006] Conventionally, there exists many devices that are capable of executing centrifugal casting process, however these existing devices fail in providing a means to save cost and reduce metallic flakes wastage, which raise problems in efficiency. In addition, these existing devices also lack in improving casting quality and reducing defects, which decreases customer satisfaction.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to be capable of preventing extra cost, reducing metallic flakes waste and human error and ensuring precise control. Furthermore, the developed device also needs to be potent enough of providing improved accuracy and consistency in casting.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of automating centrifugal casting process for reducing human error and ensuring precise control, thereby providing improved accuracy and consistency in casting, reduced labor costs, and increased productivity.

[0010] Another object of the present invention is to develop a device that is capable of efficiently measuring and dispensing metallic flakes to minimize metallic flakes waste and reduce production time, thereby saves cost, reduces metallic flakes waste, and increased efficiency in the casting process.

[0011] Yet another object of the present invention is to develop a device that is capable of ensuring uniform heating, melting, and cooling of metallic flakes to produce high-quality castings with consistent metallic flakes properties, thereby improving casting quality, reducing defects, and increasing customer satisfaction.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a vertical centrifugal casting device that is capable of automating centrifugal casting process to achieve precise control and minimize human error, while also efficiently measuring and dispensing material to reduce waste and production time, which leads to uniform heating, melting, and cooling of material, resulting in high-quality castings with consistent properties.

[0014] According to an embodiment of the present invention, a vertical centrifugal casting device, comprising a housing contains a chamber filled with metallic flakes and features a touch interactive display panel that allows users to input commands for the type of cast they want to manufacture, a microcontroller processes these inputs and determines the required amount of metallic flakes, which are then dispensed into a mixing container installed underneath the chamber through a motorized iris lid configured with the chamber, the microcontroller activates heating units integrated with the mixing container to melt the flakes into a molten metallic paste, which is then stirred by a motorized stirrer installed inside the mixing container for uniform melting, a tray with multiple ceramic molds is arranged inside the housing, and based on user input, the microcontroller positions a mold over a platform positioned underside the mixing container using a telescopically operated gripper installed inside the housing, the mold is securely gripped by electromagnets integrated into the platform, and the molten metallic paste is poured into the mold via a graphite conduit linked to the mixing container and electronic swirl nozzle and the mold platform is rotated by an electric motor coupled with the mold platform to ensure uniform distribution and solidification.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a cooling unit arranged inside the housing with Peltier units and electronically controlled valves prevents bubble formation and ensures even cooling, after casting, a slider mechanism is integrated with a horizontal plate inside the housing facilitates the removal of the cast from the mold, and a primary temperature sensor integrated within the mixing container monitors heat distribution. a pair of motorized clamping units are attached inside the housing hold the mold in place during casting, and a secondary temperature sensor is integrated with the cooling unit ensures consistent cooling throughout the entire casting process.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a vertical centrifugal casting device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a vertical centrifugal casting device that is capable of automating the casting process, ensuring precise control, minimizing human error, and optimizing material usage, leading to consistent properties and high-quality castings through uniform heating, melting, and cooling.

[0022] Referring to Figure 1, an isometric view of a vertical centrifugal casting device is illustrated, comprising a housing 101 installed with a chamber 102, a touch interactive display panel 103 is arranged on the housing 101, a motorized iris lid 104 configured with the chamber 102, a mixing container 105 installed underneath the chamber 102, a motorized stirrer 117 is installed inside the mixing container 105, a tray 106 arranged inside the housing 101 with multiple ceramic mold 107.

[0023] Figure 1 further illustrates a telescopically operated gripper 108 installed inside the housing 101, a platform 109 positioned underside the mixing container 105, multiple electronically controlled valve 110 integrated on inner walls of the housing 101, plurality of electromagnet 111 integrated into the platform 109, a graphite conduit 112 linked to the mixing container 105, via an electronic swirl nozzle 113, a horizontal plate 114 inside the housing 101, a slider mechanism 115 is integrated with the plate 114, a pair of motorized clamping units 116 are attached inside the housing 101.

[0024] The device disclosed herein, comprises of a housing 101, which severs as a mains structure of the device and developed to be placed over a ground surface. The process begins where a user provides input commands over a touch interactive display panel 103, which is installed on the housing 101 about which type of cast the user wants to manufacture. The touch interactive display panel 103 as mentioned herein is typically an LCD (Liquid Crystal Display) screen that presents output in a visible form.

[0025] The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers. A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user inputs details regarding type of cast the user desires to manufacture. A touch controller is typically connected to the microcontroller through various interfaces which may include but are not limited to PI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit).

[0026] Based on the provided input, a microcontroller of the device processes these commands and evaluate an optimal amount of the metallic flakes, which is required for manufacturing the user-specified cast. In accordance with the evaluated amount, the microcontroller actuates a motorized iris lid 104 arranged with the chamber 102 to get open and release the evaluated amount of the flakers into a mixing container 105 arranged beneath the chamber 102.

[0027] The motorized iris lid 104 is typically composed of a series of thin, overlapping blades or petals arranged in a circular or hexagonal pattern. The microcontroller sends signals to the motor of the motorized iris lid 104 to regulate the flow of flakes from the chamber 102. The motor then rotates or moves the iris blades to open the iris lid 104 to the desired position and as the motorized iris lid 104 opens the flakes are dispensed on the mixing container 105. When the determined amount of flakes is dispensed on the container 105 the microcontroller actuates the motor of the motorized iris lid 104 to rotate the blades and close the opening of the lid.

[0028] After successful accommodation of the flakes in the container 105, the microcontroller actuates multiple heating unit embedded within the mixing container 105 to melt the metallic flakes for obtaining molten metallic paste. The heating unit used herein is preferably a copper coil that generates heat when an electric current passes through the coil.

[0029] When an electric current runs through a copper wire the electrons come across the resistive forces of the medium’s material, releasing energy that is expended in the form of heat energy. The copper coil is properly insulated to prevent any heat loss and also direct the generated heat toward the flakes. The heating unit begins to generate heat and as the heating element warms up, the mixing container 105 heats the flakes and the heat causes the flakes to gradually melt. Once the microcontroller determines that the flakes have melted to the desired consistency, it turns off the heating unit.

[0030] After melting the flakes, the microcontroller actuates a motorized stirrer 117 mounted inside the mixing container 105 to stir the melted flakes, which results in uniform melting of the metallic flakes. The stirrer 117 is equipped with blades or paddles that are capable of effectively mixing the flakes when in operation. These blades are strategically positioned to create turbulence and ensure thorough mixing of the flakes. The blades or paddles of the stirrer 117 are shaped and positioned to create a vortex within the mixing container 105, ensuring that flakes are thoroughly blended. The stirrer 117 is connected to a small and powerful electric motor that provides the necessary rotatory motion to the stirrer 117 to effectively blend the stir.

[0031] Once the stirring is complete, the microcontroller actuates a telescopically operated gripper 108 mounted within the housing 101 to grip a mold 107 among multiple ceramic mold 107 from a tray 106 attached with the housing 101 and position the mold 107 on a platform 109 installed beneath the mixing container 105. The gripper 108 typically consists of two opposing arms or fingers that mimic a human hand-gripping motion. These arms are usually made of durable materials like metal or plastic to provide strength and flexibility.

[0032] A pneumatic unit is used to control movement of the gripper 108 by utilizing compressed air, which extends and retracts the gripper 108. The gripper 108 as mentioned herein are powered by a pneumatic unit that utilizes compressed air to extend and retract the gripper 108. The process begins with an air compressor which compresses atmospheric air to a higher pressure. The air cylinder of the pneumatic unit contains a piston that moves back and forth within the cylinder. The cylinder is connected to one end of the gripper 108. The piston is attached to the gripper 108 and its movement is controlled by the flow of compressed air.

[0033] To extend the gripper 108 the piston activates the air valve to allow compressed air to flow into the chamber 102 behind the piston. As the pressure increases in the chamber 102, the piston pushes the gripper 108 to the desired length for gripping the mold 107 and position it over the platform 109. Simultaneously, the microcontroller energizes multiple electromagnet 111s arranged with the platform 109 to securely accommodate the mold 107. The electromagnet 111 consists of a core material typically made of iron or steel wrapped with an insulated wire.

[0034] The wire is coiled around the core to form a solenoid. The electromagnet 111 is connected to a power source, usually a battery or a low-voltage power supply. When an electric current flows through the wire, it creates a magnetic field around the solenoid. The direction of the magnetic field depends on the direction of the current flow and as the electromagnet 111s activates, the mold 107 placed over the platform 109 securely attaches with the electromagnet 111s, thereby eliminating the chances of slippage or shaking.

[0035] The mixing container 105 having a graphite conduit 112, which allows efficient flow of the metallic paste into the mold 107 with the help of an electronic swirl nozzle 113, which is controlled by the microcontroller. The electronic nozzle 113 works by utilizing electrical energy to automize the flow solution in a controlled flow pattern by converting the pressure energy of a fluid into kinetic energy, which increases the fluid's velocity. Upon actuation of nozzle 113 by the microcontroller, the electric motor or the pump pressurizes the incoming metallic paste, increasing its pressure significantly. High pressure enables the solution to be dispensed out with a high force in the conduit 112 for dispensing the metallic paste over the mold 107.

[0036] Synchronously, the microcontroller actuates an electric motor embedded with the platform 109 to rotate the platform 109 and this rotation forms a centrifugal force, which results in pushing the metallic paste to outer edges of the mold 107 for ensuring precise distribution and solidification. After successful distribution and solidification, the microcontroller actuates a cooling unit installed within the housing 101, which is equipped with multiple Peltier units to blow cool air within the housing 101 towards outer portion of the mold 107 with the help of multiple electronically controlled valve 110.

[0037] The Peltier unit is a thermoelectric cooler that uses the Peltier effect to transfer heat from one side of the unit to the other when an electrical current is passed. The Peltier unit consists of two semiconductor materials connected in a sandwich-like fashion. These materials are typically made of bismuth telluride and one side of the Peltier unit is called the hot side and the other is the cold side. When a direct current is applied to the Peltier unit, electrodes within the semiconductor material start moving from one side to the other.

[0038] The Peltier effect occurs as a result of electron movement. When electrons flow from the cold side to the hot side, they carry heat with them. This leads to one side of the Peltier unit becoming colder, and the other side becoming hooter. This effect allows the Peltier unit to effectively transfer heat from one side to the other, creating a temperature gradient, thereby mitigating formation of any bubble while transferring the molten metal.

[0039] Once the casting process is complete, the microcontroller actuates a slider mechanism 115 arranged with a horizontal plate 114 within the housing 101 to move the cast in such manner that it gets out of the mold 107. The plate 114 mentioned herein is serves as support foundation for the cast. The slider mechanism 115 consists of a motor, and a rail unit integrated with ball bearings to allow smooth linear movement. As the motor rotates the rotational motion of the motor is converted into linear motion through a pair of belts and linkages. This linear motion provides a stable track and allows the cast move out of the mold 107.

[0040] A primary temperature sensor installed inside the mixing container 105 to detect heat flow and temperature in the molten material to ensure that the temperature is consistent or not, which results in prevention of the temperature-related defect. The core component of the temperature sensor is the sensing element which may include but is not limited to thermistors, thermocouples, or resistance detectors. The sensing element detects temperature changes on the molten metallic paste by altering its electrical properties. As the temperature increases and decreases, the resistance of the sensing element changes accordingly. The microcontroller continuously monitors the data from the temperature sensor and compares the monitored temperature with a threshold temperature.

[0041] The device features a pair of motorized clamping units 116, which is installed with the platform 109 to grip the mold 107 while casting process. The clamping unit includes a pair of flaps which are pivoted with each other for allowing the axial motion of the flaps required for clasping the mold 107, a DC motor is paired with the pivot joint that is activated by the microcontroller for providing a rotational motion to the joint for automating the movement of the flaps for gripping the mold 107.

[0042] When the outer shell has solidified, and metal inside starts to cool, the rate of cooling is carefully controlled, which ensures inner portions of casting solidify precisely. The cooling unit is having a secondary temperature sensor to detect and control heat escaping while solidification, thereby ensuring an even and consistent cooling process throughout entire casting.

[0043] The present invention works best in following manner, where the process begins with the user who needs to provide input commands regarding type of cast they want to manufacture through the touch interactive display panel 103 on the housing 101. The microcontroller processes these inputs and determines the required amount of metallic flakes, which are then dispensed into the mixing container 105 through the motorized iris lid 104. Next, the microcontroller activates the heating units to melt the metallic flakes into a molten metallic paste. The motorized stirrer 117 enhances heat distribution and promotes uniform melting. Once the melting process is complete, the microcontroller actuates the telescopically operated gripper 108 to grip and position a mold 107 over the platform 109, based on the user-specified type of shape. The electromagnet 111s securely grip the mold 107, ensuring it is held in place during the casting process. The molten metallic paste is then poured into the mold 107 via the graphite conduit 112 and electronic swirl nozzle 113. The electric motor rotates the mold 107 platform 109, creating a centrifugal force that pushes the molten metal to the outer edges of the mold 107, ensuring uniform distribution and solidification. As the molten metal flows into the mold 107, the cooling unit blows cool air inside the housing 101, directed towards the outer portion of the mold 107, to prevent bubble formation. After solidification, the slider mechanism 115 facilitates the removal of the cast from the mold 107. The motorized clamping units 116 securely hold the mold 107 in place during casting and transfer the manufactured cast to the horizontal plate 114. Throughout the process, the primary temperature sensor monitors heat flow and temperature gradients in the molten material to ensure consistent heat distribution and prevent temperature-related defects. Additionally, the secondary temperature sensor continuously monitors and controls heat escaping during solidification, ensuring an even and consistent cooling process.

[0044] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A vertical centrifugal casting device, comprising:

i) a housing 101 installed with a chamber 102 stored with metallic flakes, wherein a touch interactive display panel 103 is arranged on said housing 101 for enabling a user to give input commands regarding type of cast said user desires to manufacture;

ii) a microcontroller linked with said display panel 103 that processes said input commands and determines an amount of said metallic flakes that is to be utilized for manufacturing said user-specified cast, and accordingly actuates a motorized iris lid 104 configured with said chamber 102 to open for dispensing said determined amount of said metallic flakes in a mixing container 105 installed underneath said chamber 102 from side wall of said housing 101;

iii) plurality of heating units integrated with said mixing container 105, said microcontroller activates said heating units for melting said metallic flakes to obtain molten metallic paste, wherein a motorized stirrer 117 is installed inside said mixing container 105 to enhance heat distribution and promote uniform melting of said metallic flakes;

iv) a tray 106 arranged inside said housing 101, provided with multiple ceramic mold 107 wherein based on user-specified type of shape, said microcontroller actuates a telescopically operated gripper 108 installed inside said housing 101 to grip and position a mold 107 over a platform 109 positioned underside said mixing container 105, and simultaneously said microcontroller regulates actuation of plurality of electromagnet 111 integrated into said platform 109 to securely grip said mold 107;

v) a graphite conduit 112 linked to said mixing container 105, designed to allow molten metallic paste to flow into said mold 107 via an electronic swirl nozzle 113, wherein an electric motor is coupled with said platform 109 to rotate said platform 109, creating a centrifugal force, which pushes said molten metal to outer edges of said mold 107, ensuring uniform distribution and solidification;

vi) a cooling unit arranged inside said housing 101 and integrated with multiple Peltier units that are actuated by said microcontroller to blow cool air inside said housing 101 which is directed towards outer portion of said mold 107 by means of multiple electronically controlled valve 110 integrated on inner walls of said housing 101 during filling of said molten metal in view of preventing formation of any bubble while transferring said molten metal; and

vii) a horizontal plate 114 inside said housing 101, serving as a support structure for cast after casting process is complete, wherein a slider mechanism 115 is integrated with said plate 114, to facilitate movement of cast out of the mold 107 once casting process is complete.

2) The device as claimed in claim 1, wherein a primary temperature sensor is integrated within said mixing container 105 to monitor heat flow and temperature gradients in molten material to ensure consistent heat distribution and prevent temperature-related defect.

3) The device as claimed in claim 1, wherein a pair of motorized clamping units 116 are attached inside said housing 101 and the platform 109 to securely hold said mold 107 in place during casting process, including transferring said manufactured cast over said plate 114 post solidification.

4) The device as claimed in claim 1, wherein outer shell has solidified, and metal inside begins to cool, cooling rate is carefully controlled to ensure inner portions of casting solidify uniformly, said cooling unit is integrated with a secondary temperature sensor provided within said housing 101 to continuously monitor and control heat escaping during solidification, ensuring an even and consistent cooling process throughout entire casting.