A bull ladle and crane system can be utilized to move large volumes of metal from the primary melting furnace to the casting furnace.
Automation can provide improved process controls, reduced worker fatigue and improved productivity.
complications in using hand pour- ing ladles is the variable pour rate. Different pourers have different pour techniques, leading to inconsistency and poor process controls. Te typical metal hand ladle is prone to excessive heat loss in transfer, pouring volume limitations in large pours, worker fatigue and safety related issues. Met- alcasting facilities that have moved away from hand pouring indicate automation provides improved process
Direct Costs
Estimated Install Costs Energy Costs
Ladle Size Flexibility Heat Size Complexity Portability
Guarding Requirements Maintenance Considerations Set-Up Reach
Ability to Use Two Furnaces
Free-up Worker
Increase in Technology Unweighted Score Unweighted Rank Weighted Score Weighted Rank
Weighting Factor 10 7 3 5 8 3 7 7 5 5 7 8
9 6
controls, reduced worker fatigue, and improved productivity, as well as better metal quality and metal temperature control.
Bull Ladles & Cranes Twelve percent of those surveyed
used an “other” primary method, which included either low pressure or a bull ladle and crane system. Large transfer ladles (moved by fork truck or overhead cranes) can be used to move large quantities of metal from a primary melting furnace to the casting furnace. Tey also can be used as direct pouring ladles for large molds. Large ladles provide the benefit of
Pump
4 40 3 21 4 12 4 20 1 1
8 3
3 21 4 28 2 10 4 20 2 14 2 16
4 36 3 18
41 3
267 3
Dosing Furnace Bottom Pour Stopper Rod 1 3 4 3 4 4 2 4 2 3 1 2
10 21 12 15 32 12 14 28 10 15 7
16
4 3
40 4
246 4
36 18
2 2 4 2 3 3 3 3 4 4 3 4
3 3
43 2
269 2
20 14 12 10 24 9
21 21 20 20 21 32
27 18
being used in a separate melt treat- ment unit, where the metal can be degassed and treated with additives in batches. However, they can be prone to turbulence when pouring. Steps also are required to provide adequate safety while these large vessels are moving through the plant.
Automated Ladles Many metalcasting facilities con-
sider automatic ladles the next logical step. Of those surveyed, 12% currently employ automated ladles as their pri- mary melt transfer method. Automatic ladles provide a repeatable pouring rate, and the systems typically offer
Table 1: An engineer’s method in considering each metal transfer factor in the decision making process. Possible Methods
Power Assist 3 2 4 3 3 3 3 3 3 4 3 4
30 14 12 15 24 9
21 21 15 20 21 32
3 3
44 1
279 1
27 18
Robotics 1 1 4 3 3 3 1 1 2 1 4 4
4 4
36 6
226 6
10 7
12 15 24 9 7 7
10 5
28 32
36 24
Auto Ladling 2 2 4 3 3 3 2 2 2 2 3 3
4 3
38 5
241 5
August 2012 MODERN CASTING | 37
20 14 12 15 24 9
14 14 10 10 21 24
36 18
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