Indian Patents. 254961:THE METHOD OF POURING LIQUID METAL FROM ENCLOSED TUNDISH

Title of Invention	THE METHOD OF POURING LIQUID METAL FROM ENCLOSED TUNDISH
Abstract	This invention relates to a novel method of pouring casting by unhealed tundish pouring system for casting ferrous and non-ferrous metals and their alloys. According to this invention there is provided a novel method for pouring liquid metals by unheated tundish pouring system without stopper-rod & its servomechanism for casting ferrous and non-ferrous metals and their alloys.

Full Text	FORM 2 THE PATENT ACT 1970 (39 of 1970) & The Patents Rules,2003 PROVISIONAL/COMPLETE SPECIFICATION (See section 10 and rule 13) 1. TITLE OF THE INVENTION Movel method of pourivy system For casting. 2. APPLICANT(S) (a) NAME: RAVIMDRA R. RUKDIKAR (b) NATIONALITY: Indian, (c) ADDRESS: Fiat-20g,Buildiy-A2, Laxmiganga residency, Anandnagar, Puna-51 3. PREAMBLE TO THE DESCRIPTION PROVISIONAL COMPLETE The following specification describes the The following specification particularly describes Invention. The invention and the manner in which it is to be Performed. 4. DESCRIPTION (Description shall start from next page.) Attorhed 5. CLAIMS (not applicable for provisional specification. Claims should start with the preamble-“I/we claim” on separate page) Attorhed 6. DATE AND SIGNATURE (to be given at the end of last page of specification) 7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page) Attorhed Note. Repeat boxes in case of more than one entry. To be signed by the applicant(s) or by authorized registered patent agent. Name of the application should be given in full, family name in the beginning. Con. plete address of the application should be given stating the postal index no./code, state and country. *Strike out the column which is/are not applicable. Page-1 Field of invention: This invention relates to a novel method of pouring casting by unhealed tundish pouring system for casting ferrous and non-ferrous metals and their alloys. Background of invention: Automatic pouring system is emerging as the favorite alternative to pour casting on automatic high pressure moulding lines. There are different types of pouring systems available, which are commonly used to pour casting on these types of high pressure moulding lines. Ladle pouring by monorail, ladle pouring by crane / hoist are manual and semiautomatic options available. Ladle poring on moving trolley is also available with fully automatic and semiautomatic options. Induction heated pressure pour system and unheated tundish stopper-rod system are also used to pour using completely automatic system. Each of these systems is having their own advantages and disadvantages. Unheated tundish stopper-rod controlled pouring system is most commonly used technology in foundries. This system is having advantages of offering some buffer to melted metal from furnace, no pigging of remained metal per batch of metal, less metal spillage while pouring of metal into moulds, flexibility to change alloy, no metal as heel inside on alloy change, very low power consumption, less maintenance, can have same speed of pouring as moulding line speed, cheaper as compared to other available technologies, complete emptying in case of breakdown on moulding line. Page-2 This system is very simple, which consists of a box or tundish with refractory lining inside to hold liquid metal and the nozzle at the bottom sealed by servo driven stopper rod. Tundish is fitted on moulding line. This tundish can move on X & Y co ordinates of mould sprue cup in which metal is poured. Tundish is having filling gate to fill the metal to be poured. Lift of the stopper rod at the bottom nozzle decides start of pouring and metal flow. After filling of mould completely this stopper rod again moves down and seats on bottom nozzle, seals the metal flowing out of nozzle, this is end of pour. When a new mould comes it repeats the same cycle till the complete finish of batch of liquid metal filled in the tudish. End of pouring is decided by either weight of metal (signal of load cell), or level in the sprue cup (detected by camera or laser). This type of pouring system is mostly used for pouring cast iron, gray iron & ductile iron. But there are some disadvantages of this unheated tundish stopper rod controlled pouring system, which are as follows: a) If slag gets stuck on the seat of stopper rod on the nozzle it makes insufficient sealing of nozzle as stopper rod cannot seats fully at nozzle it results in the liquid metal loss by nozzle leakage. b) As slag of metal floats on top surface, system always needs to provide some heel metal to avoid slag to go at bottom nozzle. This causes loss of metal and other operational problems. c) Every up and down cycle of stopper rod generates stresses on stopper rod. This results in to the breakage of stopper rod during operation. This causes loss of liquid metal, reduced equipment availability, and makes operation unsafe. Page-3 d) So there is common practice in the industry w change the stopper rod at the regular frequency This increases the running cost of this pouring system and also increases equipment downtime. All these disadvantages are because of use of stopper-rc-d mechanism used for controlling the flow of liquid metal. The novel pouring system is invested to overcome these disadvantages and also add some supplementary advantages Objects of the invention: An object of this invention is to propose a novel method of pouring in unheated tundish with nozzle at bottom. Another object of this invention is to propose a novel method of pouring to avoid use of stopper rod completely. Further object of this invention is to propose a novel method of pouring liquid metal with more accurate and precise control over flow rate of liquid metal. Still further object of this invention is to propose a novel method of pouring system to minimize temperature loss of liquid metal inside the tundish and provide good fading effect in case of pouring ductile iron And to introduce new simple and cost effective pouring system. Page-4 Statement of invention: According to this invention there is provided a novel method for pouring liquid metals by unheated tundish pouring system without stopper-rod & its servomechanism for casting ferrous and non-ferrous metals and their alloys. Brief description of the accompanying drawings: The invention is explained in greater details with the accompanying drawings: Fig 1 shows the novel method of pouring by unheated tundish. Detailed description of the invention: A novel method is developed for pouring by unheated tundish automatically without stopper rod. In subsequent description said liquid metal comprises of ferrous and non-ferrous metals and their alloys. It consists of tundish (1) as shown in figure 1. It is a steel box suitable to hold liquid metal with nozzle (4) at bottom. Suitable refractory lining (2) is provided to the inside wall of tundish (1) for holding liquid metal. Tundish (1) has arrangement of filling gate (7) at the top to receive the metal to be poured. The suitable sealing gasket (3) is provided at the filling gate to seal tundish (1) after receiving the liquid metal. The sliding gate system (11) is provided at the bottom of the nozzle (4) to close the nozzle only at the time of receiving of liquid metal to be poured. A vacuum port and control valve (8) is provided on the top of the tundish (1) which is connected to suitable Page-5 vacuum system. Electrically operated gas inlet valve (9) is also provided on the top of the tundish (1) for controlling the inside pressure of the tundish (1) to control the flow of liquid metal through nozzle (4). The additional port (10) is also provided for inserting the temperature and pressure sensors At the time of receiving liquid metal to be poured sliding gate (11) seals nozzle (4) then filling gate (7) opens to receive the liquid metal. After receiving the liquid metal filling gate (7) closes and seals tundish (1). After sealing of the filling gate (7) the vacuum port (8) is opened and inside pressure of the tundish (1) is reduced by vacuum system to required level as per type of liquid metal filled. The required pressure is maintained by vacuum system. Before starting pouring operation the vacuum port (8) is closed and sliding gate (11) is opened. The pouring of liquid metal is then initiated by controlled flow of gas through gas inlet valve (9). The flow of liquid metal is also controlled by adjusting the differential pressure through valve (9). Suitable programmable logical control system is used for operating and controlling the liquid metal pouring process. The pouring operation is stopped by readjusting the pressure inside the tundish (1). This novel system offers following advantages: a) There is no requirement of stopper rod which needs frequent replacement, b) System offers precise and accurate control of liquid metal flow through nozzle, c) Minimum loss of temperature of the liquid metal inside tundish, d) Prevention of oxidation of liquid metal due to evacuation of air from the tundish. Page-6 e) The composition of liquid metal (reactive elements in the alloys) can be controlled precisely over longer period of time f) Reduced down time of the equipment (no requirement of replacing stopper rods) which means increase in the availability of system for production g) Lower running / operating cost h) Simple and cost effective operation with fully automatic controlled system i) This system is suitable for casting ferrous and non-ferrous metals and their alloys This novel method will be revolutionary in pouring technology. I Claim: 1. A novel method for pouring system by using differential pressure mechanism by creating vacuum inside tundish & then controlling the pressure by control flow of air or inert gas inside tundish at the time of pouring of liquid metal. 2. A method as recited in claim 1, wherein said liquid metal comprises of ferrous and non-ferrous metals and their alloys. 3. The method as claimed in claim 1, eliminates the use of stopper-rod & its complicated mechanism. Page-7 4. The method as claimed in claim 1, controls the flow of liquid metal precisely by readjusting the pressure inside tundish via controlled flow of gas by gas control valve 5. The method as claimed in claim 1, eliminates the oxidation of liquid metal due to removal of residual air from the tundish during evacuation. 6. The method as claimed in claim 1, reduces the temperature drop of liquid metal inside tundish 7. The method as claimed in claim 1, helps to maintain the composition of liquid metal 8. The method as claimed in claim 1, reduces the metal loss through nozzle 9. The method as claimed in claim 1, is cost effective and simple

Full Text

FORM 2
THE PATENT ACT 1970
(39 of 1970)
&
The Patents Rules,2003
PROVISIONAL/COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. TITLE OF THE INVENTION Movel method of pourivy system
For casting.

2. APPLICANT(S)
(a) NAME: RAVIMDRA R. RUKDIKAR
(b) NATIONALITY: Indian,
(c) ADDRESS: Fiat-20g,Buildiy-A2, Laxmiganga residency, Anandnagar,
Puna-51

3. PREAMBLE TO THE DESCRIPTION

PROVISIONAL COMPLETE
The following specification describes the The following specification particularly describes
Invention. The invention and the manner in which it is to be
Performed.

4. DESCRIPTION (Description shall start from next page.)
Attorhed

5. CLAIMS (not applicable for provisional specification. Claims should start with the preamble-“I/we claim” on separate page)
Attorhed

6. DATE AND SIGNATURE (to be given at the end of last page of specification)

7. ABSTRACT OF THE INVENTION (to be given along with complete specification on separate page)
Attorhed

Note.
*Repeat boxes in case of more than one entry.
*To be signed by the applicant(s) or by authorized registered patent agent.
*Name of the application should be given in full, family name in the beginning.
*Con. plete address of the application should be given stating the postal index no./code, state and country.
*Strike out the column which is/are not applicable.

Page-1
Field of invention:
This invention relates to a novel method of pouring casting by unhealed tundish pouring system for casting ferrous and non-ferrous metals and their alloys.
Background of invention:
Automatic pouring system is emerging as the favorite alternative to pour casting on automatic high pressure moulding lines. There are different types of pouring systems available, which are commonly used to pour casting on these types of high pressure moulding lines.
Ladle pouring by monorail, ladle pouring by crane / hoist are manual and semiautomatic options available. Ladle poring on moving trolley is also available with fully automatic and semiautomatic options. Induction heated pressure pour system and unheated tundish stopper-rod system are also used to pour using completely automatic system.
Each of these systems is having their own advantages and disadvantages. Unheated tundish stopper-rod controlled pouring system is most commonly used technology in foundries. This system is having advantages of offering some buffer to melted metal from furnace, no pigging of remained metal per batch of metal, less metal spillage while pouring of metal into moulds, flexibility to change alloy, no metal as heel inside on alloy change, very low power consumption, less maintenance, can have same speed of pouring as moulding line speed, cheaper as compared to other available technologies, complete emptying in case of breakdown on moulding line.

Page-2
This system is very simple, which consists of a box or tundish with
refractory lining inside to hold liquid metal and the nozzle at the bottom
sealed by servo driven stopper rod.
Tundish is fitted on moulding line. This tundish can move on X & Y co
ordinates of mould sprue cup in which metal is poured.
Tundish is having filling gate to fill the metal to be poured. Lift of the
stopper rod at the bottom nozzle decides start of pouring and metal flow.
After filling of mould completely this stopper rod again moves down and
seats on bottom nozzle, seals the metal flowing out of nozzle, this is end of
pour. When a new mould comes it repeats the same cycle till the complete
finish of batch of liquid metal filled in the tudish. End of pouring is decided
by either weight of metal (signal of load cell), or level in the sprue cup
(detected by camera or laser).
This type of pouring system is mostly used for pouring cast iron, gray iron &
ductile iron.
But there are some disadvantages of this unheated tundish stopper rod
controlled pouring system, which are as follows:
a) If slag gets stuck on the seat of stopper rod on the nozzle it makes insufficient sealing of nozzle as stopper rod cannot seats fully at nozzle it results in the liquid metal loss by nozzle leakage.
b) As slag of metal floats on top surface, system always needs to provide some heel metal to avoid slag to go at bottom nozzle. This causes loss of metal and other operational problems.
c) Every up and down cycle of stopper rod generates stresses on stopper rod. This results in to the breakage of stopper rod during operation.
This causes loss of liquid metal, reduced equipment availability, and makes operation unsafe.

Page-3
d) So there is common practice in the industry w change the stopper rod at the regular frequency This increases the running cost of this pouring system and also increases equipment downtime.
All these disadvantages are because of use of stopper-rc-d mechanism used
for controlling the flow of liquid metal.
The novel pouring system is invested to overcome these disadvantages and
also add some supplementary advantages
Objects of the invention:
An object of this invention is to propose a novel method of pouring in unheated tundish with nozzle at bottom.
Another object of this invention is to propose a novel method of pouring to avoid use of stopper rod completely.
Further object of this invention is to propose a novel method of pouring liquid metal with more accurate and precise control over flow rate of liquid metal.
Still further object of this invention is to propose a novel method of pouring system to minimize temperature loss of liquid metal inside the tundish and provide good fading effect in case of pouring ductile iron
And to introduce new simple and cost effective pouring system.

Page-4
Statement of invention:
According to this invention there is provided a novel method for pouring liquid metals by unheated tundish pouring system without stopper-rod & its servomechanism for casting ferrous and non-ferrous metals and their alloys.
Brief description of the accompanying drawings:
The invention is explained in greater details with the accompanying drawings:
Fig 1 shows the novel method of pouring by unheated tundish.
Detailed description of the invention:
A novel method is developed for pouring by unheated tundish automatically without stopper rod. In subsequent description said liquid metal comprises of ferrous and non-ferrous metals and their alloys.
It consists of tundish (1) as shown in figure 1. It is a steel box suitable to hold liquid metal with nozzle (4) at bottom. Suitable refractory lining (2) is provided to the inside wall of tundish (1) for holding liquid metal. Tundish (1) has arrangement of filling gate (7) at the top to receive the metal to be poured. The suitable sealing gasket (3) is provided at the filling gate to seal tundish (1) after receiving the liquid metal. The sliding gate system (11) is provided at the bottom of the nozzle (4) to close the nozzle only at the time of receiving of liquid metal to be poured. A vacuum port and control valve (8) is provided on the top of the tundish (1) which is connected to suitable

Page-5
vacuum system. Electrically operated gas inlet valve (9) is also provided on the top of the tundish (1) for controlling the inside pressure of the tundish (1) to control the flow of liquid metal through nozzle (4). The additional port (10) is also provided for inserting the temperature and pressure sensors
At the time of receiving liquid metal to be poured sliding gate (11) seals nozzle (4) then filling gate (7) opens to receive the liquid metal. After receiving the liquid metal filling gate (7) closes and seals tundish (1). After sealing of the filling gate (7) the vacuum port (8) is opened and inside pressure of the tundish (1) is reduced by vacuum system to required level as per type of liquid metal filled. The required pressure is maintained by vacuum system. Before starting pouring operation the vacuum port (8) is closed and sliding gate (11) is opened. The pouring of liquid metal is then initiated by controlled flow of gas through gas inlet valve (9). The flow of liquid metal is also controlled by adjusting the differential pressure through valve (9). Suitable programmable logical control system is used for operating and controlling the liquid metal pouring process. The pouring operation is stopped by readjusting the pressure inside the tundish (1). This novel system offers following advantages:
a) There is no requirement of stopper rod which needs frequent replacement,
b) System offers precise and accurate control of liquid metal flow through nozzle,
c) Minimum loss of temperature of the liquid metal inside tundish,
d) Prevention of oxidation of liquid metal due to evacuation of air from the tundish.

Page-6
e) The composition of liquid metal (reactive elements in the alloys) can be controlled precisely over longer period of time
f) Reduced down time of the equipment (no requirement of replacing stopper rods) which means increase in the availability of system for production
g) Lower running / operating cost
h) Simple and cost effective operation with fully automatic controlled
system i) This system is suitable for casting ferrous and non-ferrous metals and their alloys This novel method will be revolutionary in pouring technology.
I Claim:
1. A novel method for pouring system by using differential pressure mechanism by creating vacuum inside tundish & then controlling the pressure by control flow of air or inert gas inside tundish at the time of pouring of liquid metal.
2. A method as recited in claim 1, wherein said liquid metal comprises of ferrous and non-ferrous metals and their alloys.
3. The method as claimed in claim 1, eliminates the use of stopper-rod & its complicated mechanism.

Page-7
4. The method as claimed in claim 1, controls the flow of liquid metal precisely by readjusting the pressure inside tundish via controlled flow of gas by gas control valve
5. The method as claimed in claim 1, eliminates the oxidation of liquid metal due to removal of residual air from the tundish during evacuation.
6. The method as claimed in claim 1, reduces the temperature drop of liquid metal inside tundish
7. The method as claimed in claim 1, helps to maintain the composition of liquid metal
8. The method as claimed in claim 1, reduces the metal loss through nozzle
9. The method as claimed in claim 1, is cost effective and simple

Documents:

2010-MUM-2007-ABSTRACT(12-7-2011).pdf

2010-MUM-2007-ABSTRACT(26-12-2012).pdf

2010-MUM-2007-ABSTRACT(GRANTED)-(9-1-2013).pdf

2010-MUM-2007-CLAIMS(AMENDED)-(12-7-2011).pdf

2010-MUM-2007-CLAIMS(AMENDED)-(26-12-2012).pdf

2010-MUM-2007-CLAIMS(AMENDED)-(9-1-2013).pdf

2010-mum-2007-claims.doc

2010-mum-2007-claims.pdf

2010-MUM-2007-CORRESPONDENCE(18-12-2012).pdf

2010-MUM-2007-CORRESPONDENCE(9-1-2013).pdf

2010-MUM-2007-CORRESPONDENCE(IPO)-(9-1-2013).pdf

2010-mum-2007-correspondence-others.pdf

2010-mum-2007-description (complete).pdf

2010-MUM-2007-DESCRIPTION(GRANTED)-(9-1-2013).pdf

2010-MUM-2007-DRAWING(12-7-2011).pdf

2010-MUM-2007-DRAWING(26-12-2012).pdf

2010-MUM-2007-DRAWING(9-1-2013).pdf

2010-MUM-2007-DRAWING(GRANTED)-(9-1-2013).pdf

2010-mum-2007-drawings.pdf

2010-MUM-2007-FORM 1(26-12-2012).pdf

2010-mum-2007-form 13(12-7-2011).pdf

2010-MUM-2007-FORM 13(26-12-2012).pdf

2010-MUM-2007-FORM 18(9-10-2007).pdf

2010-MUM-2007-FORM 2(GRANTED)-(9-1-2013).pdf

2010-MUM-2007-FORM 2(TITLE PAGE)-(26-12-2012).pdf

2010-MUM-2007-FORM 2(TITLE PAGE)-(GRANTED)-(9-1-2013).pdf

2010-MUM-2007-FORM 3(26-12-2012).pdf

2010-mum-2007-form-1.pdf

2010-mum-2007-form-2.doc

2010-mum-2007-form-2.pdf

2010-mum-2007-form-3.pdf

2010-MUM-2007-MARKED COPY(26-12-2012).pdf

2010-mum-2007-other document(9-10-2007).pdf

2010-MUM-2007-REPLY TO EXAMINATION REPORT(12-7-2011).pdf

2010-MUM-2007-REPLY TO HEARING(26-12-2012).pdf

2010-MUM-2007-SPECIFICATION(AMENDED)-(26-12-2012).pdf

2010-MUM-2007-SPECIFICATIONS(AMENDED)-(12-7-2011).pdf

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Patent Number

254961

Indian Patent Application Number

2010/MUM/2007

PG Journal Number

02/2013

Publication Date

11-Jan-2013

Grant Date

09-Jan-2013

Date of Filing

09-Oct-2007

Name of Patentee

RAVINDRA R. RUKDIKAR

Applicant Address

FLAT NO. 209, BLDG A2, LAXMIGANGA RESIDENCY NEAR SUNCITY, ANAND NAGAR, PUNE

Inventors:

#	Inventor's Name	Inventor's Address
1	R. R. RUKDIKAR	FLAT NO. 209, BLDG A2, LAXMIGANGA RESIDENCY NEAR SUNCITY, ANAND NAGAR, PUNE 411051

PCT International Classification Number

B22D

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA