Foundry and plant layout method for it

Abstract

Foundry plant is simplified in article-transfer steps, reduced in transfer distance between these steps, and does not use any overhead crane. Supply/storage area ( 10 ) for materials, molds, jigs and like articles is adjacent to Working area ( 11 ) for preparing a mold and a melt, and for pouring the melt and for disassembling a flask from the mold, thereby improving the plant in both worker's production efficiency and working area's production efficiency. A multi-story warehouse ( 1 ) with a stacker crane ( 4, 4 a ) is in a central portion of the plant. A mold-making area ( 10 ) extends along one of opposite outer sides of the warehouse ( 1 ) to prepare a mold. A casting processing area ( 11 ) extends along the other outer side of the warehouse ( 1 ) thereby performing a metal melting, a melt pouring, a mold cooling, a flask disassembling, and a casting surface treatment and cleaning operation.

1 . A plant layout method for a foundry plant comprising the steps of: 
 arranging a multi-story warehouse in a central portion of said plant, said warehouse being provided with a stacker crane and a plurality of storage portions for storing therein a core pattern, a core, an empty one of completed molds before subjected to a melt pouring operation and a filled one of said completed molds after subjected to said melt pouring operation;    arranging a mold making area so as to extend along one of opposite outer sides of said multi-story warehouse, where a completed mold is prepared; and    arranging a casting processing area so as to extend along the other of said opposite outer sides of said multi-story warehouse thereby performing in said casting processing area a metal melting operation to prepare a melt, a melt pouring operation for pouring said melt into said completed mold, a cooling operation for cooling said completed mold filled with said melt, a flask disassembling operation for disassembling said completed mold to obtain a casting therefrom, and a surface treating and a cleaning operation of said casting.    
   
   
       2 . The plant layout method for the foundry plant as set forth in  claim 1 , wherein at least one of said mold making area and said casting processing area has a two-story construction to provide a lower and an upper floor portion, said upper floor portion being formed into an area for making a main pattern, a core pattern and a core.  
   
   
       3 . The plant layout method for the foundry plant as set forth in  claim 2 , wherein said lower floor portion is formed into a plurality of areas for: storing therein a metal flask; making a main mold pattern; setting said core; and, mating a cope and a drag half of said mold.  
   
   
       4 . A foundry plant comprising: 
 a multi-story warehouse arranged in a central portion of said plant, said warehouse being provided with a stacker crane and a plurality of storage portions for storing therein a core pattern, a core, an empty one of completed molds before subjected to a melt pouring operation and a filled one of said completed molds after subjected to said melt pouring operation;    a mold making area extending along one of opposite outer sides of said multi-story warehouse, where a completed mold is prepared; and    a casting processing area, which extends along the other of said opposite outer sides of said multi-story warehouse to perform a metal melting operation to prepare a melt, a melt pouring operation for pouring said melt into said completed mold, a cooling operation for cooling said completed mold filled with said melt, a flask disassembling operation for disassembling said completed mold to obtain a casting therefrom, and a surface treating and a cleaning operation of said casting.    
   
   
       5 . The foundry plant as set forth in  claim 4 , wherein at least one of said mold making area and said casting processing area has a two-story construction to provide a lower and an upper floor portion, said upper floor portion being formed into an area for making a main pattern, a core pattern and a core.  
   
   
       6 . The foundry plant as set forth in  claim 5 , wherein said lower floor portion is formed into a plurality of areas for: storing therein a metal flask; making a main mold pattern; setting said core; and, mating a cope and a drag half of said mold.