Method and apparatus for conveying sand molds

1. A method for conveying a sand mold, the method comprising:

transferring the sand mold from a sand mold forming station or metal pouring station to an accumulating conveyor including a transfer rail movable with respect to at least one fixed rail;

vertically moving the sand mold at a position between the sand mold forming station or metal pouring station and the accumulating conveyor, wherein the sand mold is vertically moved by an elevator changer fixed to the accumulating conveyor;

lifting the sand mold off the at least one fixed rail with the transfer rail;

moving the transfer rail and the lifted sand mold in a downstream direction;

lowering the lifted sand mold onto the at least one fixed rail;

moving the sand mold along the first transfer conveyor in a first direction; and

transferring the sand mold from the accumulating conveyor.

2. The method according to claim 1 , further comprising pulling the sand mold onto the accumulating conveyor.

3. The method according to claim 2 , wherein the sand mold is pulled onto the accumulating conveyor by a pulling device fixed to the accumulating conveyor.

4. The method according to claim 1 , further comprising continually sensing the position of the transfer rail as it moves between a first position along at least one of the first and second transfer conveyors.

5. The method according to claim 4 , wherein the sensing is performed by a linear displacement sensor attached to the fixed rail.

6. The method according to claim 1 , wherein the accumulating conveyor comprises a plurality of first transfer conveyors in conveying combination with a second transfer conveyor, each of the first and second transfer conveyors comprising a transfer rail movable with respect to a fixed rail.

7. The method according to claim 6 , further comprising:

transferring a plurality of sand molds from each of the plurality of first transfer conveyors to the second transfer conveyor;

moving the sand molds along the second transfer conveyor in a direction at an angle to the first transfer conveyors; and

pushing each of the sand molds off of the second transfer conveyor at a position between two adjacent first transfer conveyors.

8. The method according to claim 1 , further comprising biasing the sand mold upward from the at least one fixed rail.

9. A method for conveying a sand mold, the method comprising:

transferring the sand mold from a sand mold forming station or metal pouring station to an accumulating conveyor including a transfer rail movable with respect to at least one fixed rail;

biasing the sand mold upward from the at least one fixed rail, wherein the biasing comprises a compressed spring disposed between the sand mold and the transfer rail;

lifting the sand mold off the at least one fixed rail with the transfer rail;

moving the transfer rail and the lifted sand mold in a downstream direction;

lowering the lifted sand mold onto the at least one fixed rail;

moving the sand mold along the first transfer conveyor in a first direction; and

transferring the sand mold from the accumulating conveyor.

10. The method according to claim 9 , further comprising vertically moving the sand mold at a position between the sand mold forming station and the accumulating conveyor.

11. The method according to claim 10 , wherein the sand mold is vertically moved by an elevator changer fixed to the accumulating conveyor.

12. An apparatus for conveying sand molds, comprising:

a first transfer conveyor oriented in a first direction and including at least one transfer rail movable with respect to at least one fixed rail;

a second transfer conveyor in conveying combination with the first transfer conveyor and oriented in a second direction that is different than the first direction, the second transfer conveyor including at least one transfer rail movable with respect to at least one fixed rail;

the transfer rail of each of the first and second transfer conveyors including a frame and a plurality of carrier plates, wherein each of the plurality of carrier plates is attached along the frame by a pressurized fluid lift mechanism adapted to lift and lower a corresponding carrier plate and a sand mold; and

a transfer device attached in combination with the first transfer conveyor, wherein the transfer device transfers a sand mold from a sand mold forming station to the first transfer conveyor.

13. The apparatus according to claim 12 , wherein the transfer device comprises a puller mechanism in combination with the first transfer conveyor adapted to pull the sand mold onto the first transfer conveyor.

14. The apparatus according to claim 12 , wherein the transfer device comprises a lifting mechanism in combination with the first transfer conveyor and disposed in-stream between the first transfer conveyor and sand mold forming station.

15. The apparatus according to claim 12 , further comprising a linear displacement sensor attached to the fixed rail.

16. An apparatus for conveying sand molds, comprising:

a first transfer conveyor oriented in a first direction and including a transfer rail movable with respect to at least one fixed rail;

a second transfer conveyor in conveying combination with the first transfer conveyor and oriented in a second direction that is different than the first direction, the second transfer conveyor including a transfer rail movable with respect to at least one fixed rail;

at least one of the first transfer conveyor or the second transfer conveyor including a carrier plate fixed on the transfer rail, a lifting device disposed between the carrier plate and the transfer rail, and a biasing apparatus connected between the lifting device and the carrier plate; and

a transfer device attached in combination with the first transfer conveyor, wherein the transfer device transfers a sand mold from a sand mold forming station to the first transfer conveyor.

17. The apparatus according to claim 16 , wherein the transfer rail of each of the first and second transfer conveyors comprises a frame and a plurality of carrier plates, wherein each of the plurality of carrier plates is attached along the frame by a pressurized fluid lift mechanism adapted to lift and lower a corresponding carrier plate and a sand mold.

18. The apparatus according to claim 16 , wherein the biasing apparatus comprises a spring.

19. The apparatus according to claim 18 , wherein the lifting device includes a hydraulic or pneumatic piston, and the biasing apparatus comprises a spring block in combination with the piston and including a plurality of springs disposed between the spring block and the carrier plate.

20. The apparatus according to claim 19 , further comprising a support beam disposed between the carrier plate and the plurality of springs.