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Vector-Flo

Optimum Integration of:

  • Sand distribution system performance
  • Compaction System performance
  • Part design
  • Coating application
  • Sand fill and compaction recipe.

 

Step 1

Sand Dosing and Metering System* 

for the Lost Foam process

  • Reduce variability in sand fill height

*U.S. Patents No. 6,302,158 and 6,179,171 Existing and Pending U.S. and Foreign Patents

Steps in a "Typical" Fill and Compaction Cycle*

Step 1: Positioning Control System Moves Sensor To A "Home" Position And Uses It To Fill The Batch Hopper From Overhead.

 

 Step 2: Positioning Control System Searches For The Top Edge Of The Sand In Conjunction With The Sensor.

Step 3: Positioning Control System Moves Sensor The Distance Of Zone 1. The Sand Gate Is Opened For The Amount Of Time It Takes For Sand To Clear The Sensor.

 

 Step 4: Positioning Control System Moves Sensor The Distance Of Zone 2. The Sand Gate Is Opened For The Amount Of Time It Takes For Sand To Clear The Sensor

Step 5: Positioning Control System Moves Sensor The Distance Of Zone 3. The Sand Gate Is Opened For The Amount Of Time It Takes For Sand To Clear The Sensor

 

 Step 6: Positioning Control System Moves Sensor The Distance Of Zone 4. The Sand Gate Is Opened For The Amount Of Time It Takes For Sand To Clear The Sensor.

Advantages of the New Precision Sand Metering and Dosing System*

  • Sand dosing into flask is very accurate and repeatable
  • Dosing system automatically adjusts to changes in sand flow ability.
  • System "zone height" errors are never cumulative; always measured from a baseline.
  • System provides a maximum of flexibility and programmability versus fixed probes that extend into the flask.
Step 2

 "Two Speed" Rain Gate*

for the Lost Foam Process

  • Reduce variability in evenness of sand fill into the flask

*U.S. Patent No. 6,179,171 Existing and Pending U.S. and Foreign Patents

 

The New "Two Speed" Sand Rain Gate

New Design Provides Two Completely Different Sand Flows in One Gate*

Selection of Sand Flow Patterns is Done With a Special 3-Position Actuator

Left, Center, and Right Positions

(Safety Circuit Centers the Gate in the Event of a Power Failure or an E-Stop)

 
Detailed Assembly View of New Gate

 

Advantages of the New "Two Speed" Sand Rain Gate*

  • Simple Construction
    • No sliding surfaces to wear
  • Easy to install and adjust
  • No sensitive electrical or electronic components to fail (no calibration is required)
  • Strong rugged design
  • Very level sand fill
  • Two completely customizable rainfall patterns
    • One for slow, targeted filling
    • One for flask top-off
    • Each hole’s flow is independently adjustable

 

 

 
Step 3

 

VECTOR-FLO®
Compaction System*

for the Lost Foam Process

*Existing and Pending U.S. and foreign Patents

 

  • Design is symmetric about the flask centerline

  • Drive system designed to provide optimal flexibility of energy input

  • New clamping system "pre-stresses" structure for enhanced dynamic stiffness.

  • New integral height control system provides a maximum amount of energy isolation.

 

New Compaction System Technology

Basic Operating Principle:

  • Four separate vibration generators.

  • Each motor is independently controlled for "on the fly" phase and speed adjustment.

  • Specific combinations of motor phases can produce many different desired vibrations.

 

ImageHow it works:

  • Combinations of phase angles will produce a combination of output vibrations

  • Horizontal

  • Vertical

  • Rotational

  • Mathematically:

 

How it works:

  • The new system electronically adjusts the phase of the motors to get a desired vibration

  • Desired horizontal

  • Desired vertical

  • Desired rotationaL

  • Mathematically:
Examples:


Null Motion (Zero Vibration State)


Pure Horizontal Motion


Pure Vertical Motion



Vibratory Motor With Position Feedback 
 

Basic Schematic of Motor Operation

Advantages of the New VECTOR-FLOŽ Compaction System
  • Vibration frequency, amplitudes, and direction are all adjustable.
  • All vibration parameters can be adjusted "on the fly" during a compaction cycle.
  • Vibration parameters can be changed very quickly (< 0.3 seconds)
  • This "quick change" ability eliminates prolonged "ramp-down".
  • System mass is symmetric about the flask centerline-process parameters are uniform across the flask.
  • Sand can be made to flow in multiple directions to preferentially fill pattern cavities.
  • A "compressive" method of flask clamping pre-loads the flask and frame and creates a stiffer dynamic system.
  • An automatic leveling system maintains flask height and isolates vibration energy from the base.
  • Foundry-duty vibration motors require less maintenance and improve system serviceability.
  • The four motor system produces significantly less noise than mechanically timed systems.
  • The four motor system permits higher speeds without expensive and sensitive circulating oil lubrication systems.

With the new Vulcan VECTOR-FLO® System, all technologies work together in a uniform, complimentary design to promote operational synergy and to improve the process capabilities and repeatability of the Lost Foam process.
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