Vertical heat treatment system

Abstract

A system and method for forming and heat treating metal castings is provided with a vertical heat treatment unit positioned adjacent and downstream from a pouring station at which a series of molds are filled with a molten metal to form the castings. The vertical heat treatment unit includes a vertically oriented furnace chamber in which the castings are received, and which has a reduced footprint to reduce the manufacturing floor space required for the vertical heat treatment unit, and to enable the vertical heat treatment unit to be positioned in close proximity to the pouring station.

1 - 27 . (canceled) 
     
     
         28 . A system for forming and heat treating metal castings, the system comprising:
 a pouring station for pouring a molten metal into a mold to form the castings; and   a heat treatment unit positioned downstream from said pouring station; wherein said heat treatment unit comprises:
 a furnace defining a furnace chamber in which the castings are received; 
 a plurality of longitudinally extending conveyors positioned within said furnace, said conveyors being positioned in a vertically stacked arrangement along the furnace chamber; and 
 a series of heat sources positioned for applying heated fluid to the castings as the castings are conveyed through said furnace chamber; wherein 
 said conveyors are operated at a desired rate as needed to complete the heat treatment of the castings as said castings are passed through said furnace chamber. 
   
     
     
         29 . The system of  claim 28 , wherein said heat sources include heat sources positioned above and between said conveyors that apply heated fluid flow to the castings as the castings pass thereby or therebeneath. 
     
     
         30 . The system of  claim 28 , wherein said conveyors are chain conveyors having a series of openings defined therein. 
     
     
         31 . The system of  claim 28 , further comprising a loader mounted within said furnace chamber and adapted to move the castings onto and off of said conveyors. 
     
     
         32 . A system for forming and heat treating metal castings, the system comprising:
 a pouring station for pouring a molten metal into a mold to form the castings; and   a heat treatment unit positioned downstream from said pouring station; wherein
 said heat treatment unit comprises: 
 a furnace defining a furnace chamber in which the castings are received; 
 a grid system, mounted within said furnace chamber, said grid system having a series of chambers formed therein in which the castings are received; and 
   a series of heat sources positioned for applying heated fluid to the castings.   
     
     
         33 . The system of  claim 32 , wherein each of said chambers comprises one or both of a floor portion and a ceiling portion having a slotted construction with a plurality of openings formed therein, and wherein the castings are received and contained on chamber supports so as to allow free flow of air, heat, and dislodged sand to pass therethrough and through the entire grid system. 
     
     
         34 . The system of  claim 33 , wherein one or more heat sources are provided along one or both of said floor portions and said ceiling portions. 
     
     
         35 . The system of  claim 32 , further comprising a loader including a loader support on which one or more castings are received for introducing the castings into and removing the castings from said chambers. 
     
     
         36 . The system of  claim 35 , wherein said loader support includes a central opening in which said chamber supports are received for removal of the castings from said loader support. 
     
     
         37 . The system of  claim 35 , wherein said loader is positioned within said furnace chamber. 
     
     
         38 . The system of  claim 35 , wherein said loader is positioned outside of said furnace chamber, and wherein said loader support is moveable into and out of each of said heating chambers though an associated heating chamber opening, each heating chamber opening including a door movable between an open position and a closed position. 
     
     
         39 . A system for forming and heat treating metal castings, the system comprising:
 at least one pouring station in which a molten metal material is introduced into a series of molds; and a heat treatment unit positioned downstream from said pouring station; wherein
 said heat treatment unit comprises: 
   a heat treatment furnace mounted downstream and in proximity to said at least one pouring station; wherein
 said heat treatment furnace comprises: 
 a series of furnace chambers in which the castings are received; 
 a grid system, mounted within each of said furnace chambers, said grid system having a series of heating chambers formed therein in which the castings are received; and 
   a series of heat sources positioned for applying heated fluid to the castings.   
     
     
         40 . The system of  claim 39 , wherein said heat treatment unit is substantially circular or substantially octagonal. 
     
     
         41 . The system of  claim 39 , wherein said furnace chambers are generally C-shaped or U-shaped and include angled or curved walls, and wherein said angled or curved walls are hollow walls defining flow passages through which heated fluid flows. 
     
     
         42 . The system of  claim 39 , wherein one or more of said heat sources are mounted along one or more outer side walls of said heat treatment furnace, and wherein at least one of said one or more heat sources is respectively provided for introducing heat into each of said furnace chambers. 
     
     
         43 . The system of  claim 39 , wherein each of said heating compartments comprises one or both of a floor portion and a ceiling portion having a slotted construction with a plurality of openings formed therein, and wherein the castings are received and contained on heating chamber supports so as to allow free flow of air, heat, and dislodged sand to pass therethrough and through the entire grid system. 
     
     
         44 . The system of  claim 39 , further comprising a loader including a loader support on which one or more castings are received for introducing the castings into and removing the castings from said chambers. 
     
     
         45 . The system of  claim 44 , wherein the castings are received and contained on heating chamber supports, and wherein said loader support includes a central opening in which said heating chamber supports are received for removal of the castings from said loader support. 
     
     
         46 . The system of  claim 44 , wherein said loader is positioned within said heat treatment unit approximately at a center of said heat treatment unit. 
     
     
         47 . The system of  claim 44 , wherein one or more of said heat sources are positioned for applying heat through or along said loader.