Mold Handling System

Abstract

A mold handling manufacturing line, which includes at least a first subline and a second subline, is provided. The mold handling manufacturing line moves at least one mold car that supports a cast mold, which forms a cast part, the mold handling manufacturing line comprising at least a first subline and a second subline and a first transfer station. The second subline is located substantially parallel with and spaced apart from the first subline. The first transfer station in communication with the first subline and the second subline. The first transfer station includes a transfer cart configured to receive the at least one mold car. The first transfer station includes a servo belt driven line composed of a servo motor rotates one or more drive pulleys, via a belt. which is coupled to the transfer cart. When the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the first subline and the second subline. Also, when the servo motor rotates in a second rotational direction, it causes the belt, positioned on the one or more drive pulleys, to move the transfer cart in a second linear direction between the first subline and the second subline.

What is claimed: 
     
         1 . A mold handling manufacturing line that moves at least one mold car that supports a cast mold which forms a cast part, the mold handling manufacturing line comprising:
 a first subline;   a second subline located substantially parallel with and spaced apart from the first subline;   a third subline located substantially parallel with and spaced apart from the first subline and the second subline;   a fourth subline located substantially parallel with and spaced apart from the first subline, the second subline, and the third subline;   a first transfer station in communication with the fourth subline and the first subline;
 wherein the first transfer station includes a transfer cart configured to receive the at least one mold car; 
 wherein the first transfer station includes a servo belt driven line composed of a servo motor that is about centrally located with respect to the first transfer station and rotates one or more drive pulleys via a belt; 
 wherein the belt is coupled to the transfer cart; 
 wherein, when the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the fourth subline and the first subline; 
 wherein, when the servo motor rotates in a second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a second linear direction between the fourth subline and the first subline; and 
   a second transfer station located distal from the first transfer station;
 wherein the second transfer station is in communication with the first subline, the second subline, the third subline; and the fourth subline; 
 wherein the second transfer station includes a first transfer cart configured to receive the at least one mold car and a second transfer cart configured to receive another at least one mold car; 
 wherein a servo actuator, as part of the second transfer station, moves a rod in the first linear direction and the second linear direction; and 
 wherein the rod is attached to the first transfer cart of the second transfer station and the second transfer cart of the second transfer station, so that the first transfer cart of the second transfer station and the second transfer cart of the second transfer station are movable in the first linear direction and the second linear direction together as the rod correspondingly moves in the first linear direction and the second linear direction to move the first transfer cart of the second transfer station between the first subline and the second subline and the second transfer cart of the second transfer station between the third subline and the fourth subline. 
   
     
     
         2 . The mold handling manufacturing line of  claim 1 , wherein the one or more drive pulleys of the first transfer station includes a first pulley and a second pulley wherein the first pulley is spaced apart from the second pulley and spans a distance that is at least a length of travel of the first transfer cart. 
     
     
         3 . The mold handling manufacturing line of  claim 1 , wherein when the servo motor rotates in the first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in the first linear direction to the fourth subline, when the servo motor rotates in the second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in the second linear direction to the first subline. 
     
     
         4 . The mold handling manufacturing line of  claim 1 , further comprising an index actuator that operates adjacent the first transfer station and the first subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein when the transfer cart of the first transfer station is located adjacent the first subline the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the first transfer station onto the first subline. 
     
     
         5 . The mold handling manufacturing line of  claim 1 , further comprising an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline. 
     
     
         6 . The mold handling manufacturing line of  claim 1 , further comprising an index actuator that operates adjacent the second transfer station and the fourth subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the second transfer cart of the second transfer station is located adjacent the fourth subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the another at least one mold car in order to pull the another at least one mold car from the transfer cart of the second transfer station onto the fourth subline. 
     
     
         7 . The mold handling manufacturing line of  claim 1 , wherein the servo actuator of the second transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the first transfer cart of the second transfer station and the second transfer cart of the second transfer station attached. 
     
     
         8 . The mold handling manufacturing line of  claim 6 , wherein the servo actuator of the index actuator rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the indexing block attached. 
     
     
         9 . The mold handling manufacturing line of  claim 6 , further comprising a third transfer station located distal from the second transfer station, wherein the third transfer station is in communication with the second subline and the third subline, wherein the third transfer station includes a transfer cart configured to receive the at least one mold car, wherein a servo actuator, as part of the third transfer station, moves a rod in the first linear direction and the second linear direction, and wherein the rod is attached to the transfer cart of the third transfer station so that the transfer cart of the third transfer station is movable in the first linear direction and the second linear direction as the rod correspondingly moves in the first linear direction and the second linear direction to move the transfer cart of the third transfer station between the second subline and the third subline. 
     
     
         10 . The mold handling manufacturing line of  claim 9 , wherein the servo actuator of the third transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the third transfer station attached. 
     
     
         11 . The mold handling manufacturing line of  claim 1 , further comprising a jacket lift assembly configured to place a mold jacket over a mold on the at least one mold car, wherein the jacket lift assembly includes one or more jacket lift arms, wherein a servo actuator includes an extendable rod that is attached to a frame, which is attached to the one or more jacket lift arms to extend or retract the one or more jacket lift arms. 
     
     
         12 . The mold handling manufacturing line of  claim 11 , wherein the servo actuator of the jacket lift assembly rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the frame of the jacket lift assembly attached. 
     
     
         13 . The mold handling manufacturing line of  claim 1 , further comprising a sand push off station configured to remove the cast mold made of sand from the at least one mold car, wherein the sand push off station includes a jacket lift actuator assembly and a push off actuator assembly, wherein the jacket lift actuator assembly includes a jacket lift servo actuator that is configured to selectively raise and lower one or more jacket lift arms, via a frame, to remove a jacket prior to removing the sand from the cast mold on the at least one mold car, and wherein the push off actuator assembly includes a push off servo actuator that has an extendable rod which moves the jacket lift actuator assembly so that after the jacket lift actuator assembly lifts the jacket from a mold, the push off servo actuator is configured to move the jacket lift actuator assembly and the mold seated on the at least one mold car. 
     
     
         14 . The mold handling manufacturing line of  claim 13 , wherein the push off servo actuator of the push off actuator assembly rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the frame of the push off actuator assembly attached. 
     
     
         15 . A mold handling manufacturing line that moves at least one mold car that supports a cast mold, which forms a cast part, the mold handling manufacturing line comprising:
 at least a first subline and a second subline;   wherein the second subline is located substantially parallel with and spaced apart from the first subline;   a first transfer station in communication with the first subline and the second subline;
 wherein the first transfer station includes a transfer cart configured to receive the at least one mold car; 
 wherein the first transfer station includes a servo belt driven line composed of a servo motor that is about centrally located with respect to the first transfer station and rotates one or more drive pulleys via a belt; 
 wherein the belt is coupled to the transfer cart; 
 wherein when the servo motor rotates in a first rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a first linear direction between the first subline and the second subline; and 
 wherein when the servo motor rotates in a second rotational direction, it causes the belt positioned on the one or more drive pulleys to move the transfer cart in a second linear direction between the first subline and the second subline. 
   
     
     
         16 . The mold handling manufacturing line of  claim 15 , wherein the servo motor of the first transfer station rotates a ballscrew, which linearly moves a rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the first transfer station attached. 
     
     
         17 . The mold handling manufacturing line of  claim 15 , further comprising an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline. 
     
     
         18 . A mold handling manufacturing line that moves at least one mold car that supports a cast mold, which forms a cast part, the mold handling manufacturing line comprising:
 At least a first subline and a second subline;   wherein the second subline is located substantially parallel with and spaced apart from the first subline;   a first transfer station in communication with the first subline and the second subline; and   wherein the first transfer station includes a transfer cart configured to receive the at least one mold car, wherein a servo actuator as part of the third transfer station moves a rod in a first linear direction and a second linear direction, and wherein the rod is attached to the transfer cart of the first transfer station so that the transfer cart of the first transfer station is movable in the first linear direction and the second linear direction as the rod correspondingly moves in the first linear direction and the second linear direction to move the transfer cart of the first transfer station between the first subline and the second subline.   
     
     
         19 . The mold handling manufacturing line of  claim 18 , wherein the servo actuator of the first transfer station rotates a ballscrew, which linearly moves the rod, which includes a thrust tube, and a ball nut attached to the thrust tube and includes one or more concentric threads of ball bearings that ride along corresponding threads of the ballscrew such that, as the ballscrew rotates, it moves the ball nut and the thrust tube linearly with the transfer cart of the first transfer station attached. 
     
     
         20 . The mold handling manufacturing line of  claim 18 , further comprising an index actuator that operates adjacent the second transfer station and the second subline, wherein the index actuator includes a servo actuator that rotates to move a rod that is also attached to an indexing block, wherein a dog is pivotable about a pivot pin on the indexing block, wherein the dog is biased in a first pivot direction, wherein a stop is engageable with the dog to limit movement of the dog in the first pivot direction, wherein, when the first transfer cart of the second transfer station is located adjacent the second subline, the servo actuator rotates to extend the indexing block, wherein the dog is configured to engage the at least one mold car in order to pull the at least one mold car from the transfer cart of the second transfer station onto the second subline.