Apparatus, plant and method for producing ingots and metal bars and for monitoring the quality thereof

Abstract

An apparatus for producing metal bars and ingots with quality monitoring, includes at least one mold essentially constituted by a body that forms at least one cavity for forming an ingot or a bar and by at least one cover that is detachably associated with the body in order to upwardly close the cavity. The apparatus has at least one passage, provided on the body of the mold, on the cover or on both, for connecting the inside of the cavity to the outside even when the cover is associated with the body in order to upwardly close the cavity. The apparatus according to the invention also has the particularity that it includes a means for taking a sample of the melted material contained in a mold, constituted essentially by a body that forms at least one cavity for forming an ingot or a bar and by at least one cover that is detachably associated with the body in order to upwardly close the cavity. The present invention also relates to a plant and a method for producing metal bars and ingots with quality monitoring.

1 . An apparatus for producing metal bars and ingots with quality monitoring, comprising:
 at least one mold comprising:
 a body forming at least one cavity configured to form an ingot or a bar; and 
 a cover detachably coupled to said body and configured to upwardly close said cavity wherein at least one of said body and said cover comprises a passage configured to connect the inside of said cavity to the outside of said mold when said cover is coupled to said body upwardly closing said cavity. 
   
     
     
         2 . The apparatus according to  claim 1 , wherein said body and said cover comprise slots that together form said passage. 
     
     
         3 . The apparatus according to  claim 1 , wherein the mold is configured to receive material for producing the metal bars and ingots, and said passage is configured to allow the insertion of a sample taking device in said cavity for taking a sample of the material in the molten state. 
     
     
         4 . The apparatus according to  claim 3 , wherein:
 said mold comprises a secondary cavity for forming a sample to be assayed, said secondary cavity being provided in said body or on said cover; and   said passage is configured to allow the insertion of a substantially rod-shaped member that is configured to cause a temporary increase in the level reached by said material after melting.   
     
     
         5 . An apparatus for producing precious metal bars and ingots with quality monitoring, comprising:
 a sample taking device for taking a sample of the melted material contained in a mold; said mold comprising a body forming at least one cavity for forming an ingot or a bar and at least one cover detachably coupled to said body to upwardly close said cavity.   
     
     
         6 . The apparatus according to  claim 5 , wherein said sample taking device is inserted in said cavity using at least one passage that is provided in said mold in order to connect the inside of said cavity to the outside of said mold, even when said cover is coupled to said body to upwardly close said cavity. 
     
     
         7 . The apparatus according to  claim 5 , wherein said sample taking device is inserted in said cavity by lifting said cover so as to open said cavity temporarily. 
     
     
         8 . The apparatus according to  claim 5 , wherein said sample taking device comprises a substantially hollow container body that is made of a material resistant to high temperatures, said container body having at least one opening for inserting the melted material. 
     
     
         9 . The apparatus according to  claim 8 , wherein said container body comprises an elongated tubular body made of a material resistant to high temperatures, said tubular body including a through hole formed longitudinally therein, said opening for the entry of the melted material being formed at a first end of said tubular body. 
     
     
         10 . The apparatus according to  claim 9 , wherein said tubular body comprises at least one receptacle connected to said opening for the entry of the melted material and preset to contain a calibrated quantity of the melted material contained initially in said cavity. 
     
     
         11 . The apparatus according to  claim 9 , wherein said tubular body comprises a plurality of receptacles arranged in succession, said receptacles being mutually connected by breakable ducts. 
     
     
         12 . The apparatus according to  claim 8 , wherein said sample taking device comprises a depressurization unit functionally connected to said container body, said depressurization unit being preset to aspirate a gaseous medium contained in said container body so as to draw a calibrated quantity of the melted material, initially contained in said cavity, into said container body. 
     
     
         13 . The apparatus according to  claim 12 , wherein said depressurization unit comprises at least one vacuum pump, the vacuum pump being operated manually or automatically. 
     
     
         14 . The apparatus according to  claim 8 , wherein said container body comprises at least one vacuum test piece made of a material resistant to high temperatures, a breakable region provided at a first end of said test piece being preset to break upon contact with said melted material to form at least one opening for the inflow of the melted material, said test piece being configured to contain a calibrated quantity of the melted material initially contained in said cavity. 
     
     
         15 . The apparatus according to  claim 8 , wherein said container body comprises a hollow tip made of a material resistant to high temperatures and removably associated with a tubular support, at least one opening for inserting the molten material being formed at a first end of said hollow tip, said hollow tip being preset to contain a measured quantity of the molten material contained initially in said cavity. 
     
     
         16 . The apparatus according to  claim 8  wherein said container body comprises a concave shovel made of a material resistant to high temperatures and associated with a rod-like support, said shovel being preset to contain a calibrated quantity of the melted material initially contained in said cavity. 
     
     
         17 . The apparatus according to  claim 16 , wherein said sample taking device is associated with said mold. 
     
     
         18 . A plant for producing metal bars and ingots with quality monitoring, comprising:
 a melting station including a heating chamber configured to accommodate a mold; said heating chamber being provided with an access opening controlled by a movable bulkhead; said mold comprising a body that defines a cavity for forming an ingot or a bar, and a cover that is detachably coupled to said body in order to upwardly close said cavity; wherein said heating chamber comprises a gap configured to allow to reach said mold from the outside even when said access opening is substantially closed.   
     
     
         19 . The plant according to  claim 18 , comprising a sample taking device for taking a sample of the melted material contained in said cavity; said sample taking device being insertable within said cavity using at least one passage formed in said mold to connect the inside of said cavity to the outside of said mold, even when said cover is associated with said body for upwardly closing said cavity. 
     
     
         20 . The plant according to  claim 18 , wherein said sample taking device is inserted in said heating chamber using said gap. 
     
     
         21 . A method for producing metal bars and ingots with quality monitoring, comprising the steps of:
 introducing a precise amount of material to be melted into a cavity for forming an ingot, or a bar, formed in the body of a mold;   detachably associating a cover with said body so as to upwardly close said cavity;   heating said mold until said material melts;   taking a sample of the melted material contained in said cavity.   
     
     
         22 . The method according to  claim 21 , wherein said taking of said sample is performed while keeping said cover in the closed position. 
     
     
         23 . The method according to  claim 21 , wherein said taking of said sample is performed by inserting a sample taking device in said cavity through a passage formed in said mold to connect the inside of said cavity to the outside of said mold, even when said cover is associated with said body for upwardly closing said cavity; said sample taking device being preset to take a calibrated quantity of the melted material contained in said mold. 
     
     
         24 . The method according to  claim 21 , wherein said taking of said sample is performed by lifting said cover so as to open said cavity temporarily. 
     
     
         25 . The method according to  claim 21 , wherein said taking of said sample is performed by a sample taking device associated with said mold.