Two core production
cells for WEG
Flexibility and experience in automation
Few industries can now ignore the use of robots,
every year their numbers are growing and there
is still no end in sight.
The German company Laempe & Mössner was, at an early stage,
aware of how important it is for foundries to automate their workflow
to speed up production cycles and ensure consistent, high quality.
These are two important points at a time when production cycles are
becoming ever shorter and quality an increasingly competitive factor.
That is why the company has, for many years, offered individual
automated solutions, every system is adapted individually to
customer needs. Despite numerous module solutions, which can be
composed like a construction kit into a complete core assembly cell,
every solution requires new ideas from the project managers - one
reason why Laempe holds numerous patents worldwide in the field of
different robotic solutions.
Golden Robot Award
Robot Award 2001. This tribute was received for
development work in the field of industrial robot
technology. The judges reported: ‘Laempe has
sustainably contributed to the robotisation of the
foundry’.
It was also stated that Laempe had
‘considerably contributed’ to the increase in
efficiency of many foundries. Furthermore, the
jury recognised the engagement and acceptance
of the challenge on the difficult process of
automating casting cleaning.
The company considers itself as a system
supplier for coremaking shops, claiming to be a
global market leader in this type of automation.
It currently supplies between 30 and 40 robots
each year - an increasing trend. Statistically, this
means that the company delivers a robot with
every third or fourth core shooter.
One of the numerous honours in the company’s history is the Golden
WEG wants to become number one
Production hall at Laempe & Mössner
During 2008, the first two core production cells,
as well as the storage and transport system
and the disposal unit with camera system
will be installed and commissioned at WEG
Equipamentos Eléctricos SA in Jaragua do Sul SC,
Brazil.
WEG was elected by the Boston Consulting
Group as one of the fastest growing companies
worldwide. Furthermore, it is one of the
leading companies supplying electric motors
internationally and aims to become number one.
For WEG, the decision to choose Laempe as
its supplier was clear, as it wanted to produce
premium products in a fully automatic foundry.
Because of this, Laempe was responsible for the
228
FTJ September 2008
Mould and Coremaking
delivery of the core production and assembly
system, peripheral equipment and its automation
and for the transfer of the core package to the
moulding line.
Whilst Laempe supplied most of the facility,
the camera system came from Cognex, the
screws and the screwing unit from Stöger
Automation, the high bay warehouse from SSI
Schäfer and the robots from ABB. All other
components were fabricated by Laempe - or at
least assembled in-house.
Construction, production and assembly, as
well as implementation on-site all interlock
requiring a good line of communication as
there are frequent changes introduced into the
project during construction and production. The
smallest alteration to say the core box can result
in changes within the whole project including the
gripper, the positioning of the robots, changes
on the defining station, the sand core delivery
or on the screwing unit. Laempe is able to react
flexibly at any time during a project and is always
able to produce high quality end products.
Together with WEG, Laempe developed a
concept for fully automated sand core production
with delivery to the moulding line. The core box
has also been developed to ensure that the sand
cores are easily integrated into any part of the
process.
The whole project includes several automated,
independent core production cells incorporating
robots for core removal, defining, spray coating,
FTJ September 2008
screwing, plus the disposal of the sand core package to the storage
and transport system, the conveyor delivering the sand core package
via a drying oven in a high-bay warehouse. The sand core packages
are then delivered to the disposal unit. Sand cores are in an undefined
position on a pallet, the position is located using a camera system
and carried to the moulding line by a robot.
Fast product change is possible with the different gripper racks for
the change of the robot grippers, as well as the tool changer for core
box change on the core shooter.
Laempe & Mössner GmbH. Tel: +49 (0) 7622 6800;
email: info@laempe.com web: www.laempe.com
Staff working on the core production cell
229
Moulding and Coremaking
Tried and tested on a world tour
FTL’s Moldmaster high pressure greensand moulding
technology has been popular in the UK for 30 years, the
last ten of which have seen it emerge as a viable solution in
other countries.
FTL has also been supplying its automated no-bake
moulding lines to Turkey and Russia for the past decade
and is now witnessing a growth in the need for a wider
range of moulding solutions as they develop their foundries
to compete with the best of the rest.
The familiar robust nature of FTL moulding and coremaking
equipment is an instantly recognisable feature in many UK foundries
where the company has commissioned and installed more kit than
any other supplier in the market.
With a reputation built on understanding foundries’ needs and
the supply of reliable equipment installed on time which delivers
what it promises, FTL has dominated the UK market for many years.
Predominantly known for no-bake moulding and high pressure
greensand moulding solutions, FTL equipment graces the shopfloor
of many foundries in the UK, Europe and Scandinavia proving reliable
year after year.
More recently a growing number of foundries in Turkey and Russia
have been commissioning FTL equipment, born out of a need for
reliable and well engineered equipment.
FTL is particularly successful in the field of no-bake moulding
where higher production rates and accurate castings are achieved
with automated pattern re-circulation loops, transfer cars and
powered tracks.
These lines can be used for iron, steel or aluminium casting of
short to medium series production with mould sizes up to 3000mm
by 1800mm.
Turkish foundry Odoksan Osmaneli Dokum Sanayi AS looked to
FTL when it needed to find a solution to help produce reproduction
Victorian metal baths requiring half mould sizes of 1000mm x 2000m
x 850mm. FTL designed and installed a complete furane moulding
230
30tph articulated mixer and automated mould handling
plant with rollover strip machine and powered transfer
car in Turkey
system and sand reclamation plant at the
foundry.
The automated system is capable of
circulating up to 16 bolsters/hour to produce
eight complete moulds. There is one fill station,
one strip station, five curing stations and two
pattern change/curing stations. A transfer car
automatically sequences bolster plates carrying
patterns between filling, stripping and curing
stations.
At the rollover station the bolster and pattern
are rolled over through 180 degrees. After
vibration the stripped half moulds are transferred
to a pre-heat station ready for painting. The half
mould is lifted by a manipulator and moved to
the paint station. After painting and drying, cores
are inserted before the completed half moulds
are placed and closed onto a pallet ready for
pouring and cooling. The cooled moulds and
castings then travel to a shakeout where they are
separated from the sand and the empty pallets
returned to the pouring line to receive new
moulds.
The castings are lifted off by a post jib and
hoist, the sand falls through to a conveyor belt
below which feeds a surge hopper and attrition
reclaimer up to 15-20 tonnes/hour.
The reclaimed sand is then classified and
cooled ready for reuse.
Fellow Turkish foundry Buyuk Eker opted for
FTL’s world-renowned Moldmaster technology to
FTJ September 2008
Moulding and Coremaking
help it develop new markets for its castings but it
also provided an economical option. The foundry
currently supplies brake components to European
heavy vehicle manufacturers.
FTL installed a three station, high pressure
greensand Moldmaster line suitable for
production of SG or grey iron castings. The 6070 moulds/hour line has one pouring line and
three cooling lines. Mould transfer is by hydraulic
pushers and electrically powered transfer cars.
Following installation the foundry reports that
production rates are significantly higher. They
also report a metal saving of 5-10% which they
attribute to the production of nearer to net shape
castings because of the higher intensity of the
mould.
Safak Dokum Makina Parca Sanayi Ve Ticaret
AS already has a three station Moldmaster with
a capacity of 100 moulds/hour, size 850mm x
850mm by 350mm x 350mm. The automated
plant includes an 80 tonnes/hour FTL sand plant
with FTL mixer and moisture control which has
been in operation for a number of years.
The Moldmaster concept has proved popular
with foundries in many countries for many years
because it can be adapted to suit specific iron
foundry needs. It can be configured with a two or
three station layout, as a duplex arrangement to
suit smaller box sizes, rotary indexing machines
and in-line Moldmasters for high output rates on
a single pass line.
Previously cored parts can be moulded and
casting weights can be reduced maintaining tight
mould tolerances and rigidity.
The new generation Moldmasters are as
versatile and reliable as those installed a quarter
of a century ago. Indeed FTL prides itself on
still providing after care and advice to foundries
with FTL moulding equipment older than their
apprentice workers. Some foundries have also
chosen to upgrade the existing equipment to
meet changing needs or growing capacities.
Whether its high pressure greensand
moulding, no-bake moulding or indeed lost foam
moulding there looks set to be plenty more FTL
equipment about in the future.
John Griffiths of FTL is in no doubt why Turkish
and Russian foundries are waking up to the
40tph articulated
mixer in a steel
foundry in Russia
appeal of the company’s extensive range of moulding solutions. ‘FTL
plants are reliable and we work with respected agents. We installed
a Moldmaster in Turkey nine years ago to produce brake discs, since
then we have two other plants up and running and lots of individual
bits of kit’, he said. ‘Russia is also another growth market for us with
lots of projects being undertaken at the moment.’
‘The most recent Russian order was signed at the Moscow
exhibition for a complete automatic moulding loop and casting
lines for manufacturing precision S/S valves working in conjunction
with existing FTL mixer and reclamation equipment that has been
operating very successfully in the foundry for several months.’
FTL has forged a very successful partnership with Rodonit Limited
a very well respected engineering company and supplier of resins
and mould materials which is based in St Petersburg, Russia. Rodonit
has for some years now provided on site installation, commissioning
and after sales service which has been an essential ingredient in the
total service provided by FTL. For more information contact: Dr Yuri
Muravjev, email: yuri2:Rodonit@rambler.ru
Following on from the very successful formulae adopted in Russia,
FTL has set up its own office in Konya, Turkey again providing full
installation, commissioning and after sales back-up for FTL plants
supplied in Turkey. For more information contact: Burak Cagli,
email: burak.cagli@ftl-foundry.co.uk
FTL is also planning to build on its reputation in Turkey at the
Ankiros exhibition in October 2008.
Moldmaster may be a tried and tested method but it is currently on
quite a world tour.
For more information contact: John Griffiths on Tel: +44 (0) 1902 630222.
email: sales@ftl-foundry.co.uk web: www.ftl-foundry.co.uk
High-frequency de-coring
One of the innovative products for the foundry industry from R Scheuchl GmbH is
its Shake Champion SC 420 de-coring machine.
Suitable for use on sand and diecastings in weights up to 160kg, the principle on which the SC 420 operates is
high-frequency vertical oscillation with amplitudes up to 36mm.
After fixing the part in the clamping system, it is exposed to vertical oscillation, the broken sand is agitated up
and down against the casting wall, the sand then disintegrates. The loose sand is ejected by the oscillation from
the openings in the casting and discharged via an integral conveyor system.
Due to the high frequency combined with high swing amplitude, de-coring time is minimised and is most
effective.
For additional information visit www.scheuchl.de
FTJ September 2008
231
Moulding and Coremaking
Coremaking and high-density moulding the route to a world-class foundry
A world-class foundry is one fit to operate in the
global market. Italian equipment specialist, Fritz
Hansberg SpA, elaborates.
If the core shop in a traditional and a world-class foundry are
compared, we are likely to find a situation as shown in fig. 1. The
road from the traditional to the world-class core shop is without
doubt a quality-driven revolution, enhancing casting quality by
reducing core scrap and variation.
The single highest cause for core scrap/variation is manual
handling of individual cores - core dressing (defining); core coating;
core storage/transfer and core setting. The proven solution to this is
to automate the core production process and handle complete core
assemblies as opposed to individual cores.
A world-class core shop requires world-class engineering which
involves not only the core machines but also the tooling, together
with tight control of the process and methods. This needs highperformance core machines, automatic core definning, assembly, and
handling facilities.
High-performance core machines operating with horizontal-split
tooling are best suited for integration into fully automatic core
manufacturing facilities.
It is important to note that with automation of core production
and handling the core machine, together with every other piece of
equipment, must operate for long periods without stopping or the
FRITZ HA NSB ER G
whole production process will be jeopardised. This is not the case in
the traditional core shop where one or more back-up machines are
normally available so that down time on any single machine is not
usually critical to the process as a whole.
core set as a whole, and must be consistently
kept under stringent process control during
production.
Tasks such as core pick-off, definning,
assembly, transport, setting, etc are performed
automatically with the aid of gantry manipulators
and industrial robots. Core handling equipment
design involves thorough co-engineering with the
customer, and is always the result of in-depth
technical interchange between the supplier and
the foundry’s tooling, process and methods’
engineers.
Automatic core definning can be achieved
using gantry manipulators or core pick-off robots
and definning devices of various constructions
(masks, brushes, chains, etc) with various
degrees of success. However, when definning
with precision and consistency become critical,
definning systems that eliminate unnecessary
core handling will be the choice.
The most widespread and probably most
accurate and cost-effective method of automatic
assembly for heavy core packages such as motor
block cores, is to bolt the package using tie-rods
and locking nuts, insuring both high mechanical
stability and tight dimensional tolerances.
S.p.A.
Alternative methods of package assembly include
gluing with hot and cold glue, and sand bolting,
whereby a connecting sand element is shot
through a channel running through the package.
Lighter cores are successfully assembled by
screwing or gluing, hot melt glue and cold glue
are used depending on the specific application.
While cold glue requires hours to set, hot glue
sets hard in a few seconds and it is therefore
particularly suited for use in association with
automatic core handling.
CORE MAKING AND HIGH-DENSITY MOLDING
THE WAY TO A WORLD-CLASS FOUNDRY
The modern approach
High-performance core machines aligned to modern cold box core
making processes are designed for use in association with multiplecavity tooling. The complete core requirement for one or more
core assemblies is produced in the same core box, regardless of
A world-class
foundry
fit toand
operate
in This
the global
market.
their foundry
diversityisina size,
shape,
mass.
approach
obviously
demands a high degree of process control. All process parameters,
If we compare
Shop in of
a traditional
a world-class
foundry
we are likely to find:
from the
theCore
percentage
resin and and
hardener,
to shoot
and gas/purge
The moulding line
parameters, must be optimised for both the individual cores and the
– high density vs greensand
The Core Shop
TRADITIONAL
TRADITIONAL
CORE
CORESHOP
SHOPCONCEPT
CONCEPT
SHELL
SHELL/ /HOT
HOT-BOX
-BOXPROCESS
PROCESS
MANY,
MANY,SMALL
SMALLMACHINES
MACHINES
VERTICAL
VERTICAL-SPLIT
-SPLITTOOLING
TOOLING
AUTOMATIC
AUTOMATIC
CORE
CORESETTING
SETTING
STORAGE
STORAGE/ /TRANSFER
TRANSFEROF
OF
CORE
COREASSEMBLIES
ASSEMBLIES
AUTOMATIC
AUTOMATIC
CORE
COREASSEMBLY
ASSEMBLY
SINGLE
SINGLE-CAVITY
-CAVITYTOOLING
TOOLING
AUTOMATIC
AUTOMATIC
CORE
COREDEFINNING
DEFINNING
MANUAL
MANUAL
CORE
COREDEFINNING
DEFINNING
MULTIPLE
MULTIPLE-CAVITY
-CAVITYTOOLING
TOOLING
STORAGE
STORAGE/ /TRANSFER
TRANSFEROF
OF
INDIVIDUAL
INDIVIDUALCORES
CORES
MANUAL
MANUAL
CORE
COREASSEMBLY
ASSEMBLY
MANUAL
MANUAL
CORE
CORESETTING
SETTING
Fig. 1
THE
CORE SHOP
REVOLUTION
HORIZONTAL
HORIZONTAL-SPLIT
-SPLITTOOLING
TOOLING
FEW,
FEW,LARGE
LARGEMACHINES
MACHINES
COLD-BOX
COLD-BOXPROCESS
PROCESS
WORLD-CLASS
WORLD-CLASS
CORE
CORESHOP
SHOPCONCEPT
CONCEPT
If we are to achieve close dimensional tolerance
with repeatability in the manufacture of castings,
then both cores and moulds become of equal
importance.
High-density moulding is typified by the
ability of transferring high-pressure values to the
mould (typically ranging between 7 and 14 kgf/
cm2). This results in a mould that is more dense
and tightly packed, with higher mould surface
hardness (85-95° B-scale) capable of producing
castings with greater dimensional and mass
stability.
Mould compaction is achieved by various
methods involving the conversion of the energy
generated by the application of compacting
forces into compaction work. The effectiveness
of each moulding method is measured against
its ability to faithfully reproduce the shape of the
pattern and consistently produce dimensionally
accurate castings.
The road from the traditional to the world-class core shop is without doubt a quality-driven
revolution: enhancing casting quality by reducing core scrap and variation.
232
The single highest cause for core scarp/variation is manual handling of individual cores:
FTJ September 2008
Using gravity to evenly feed and distribute lump free sand onto the entire surface of the pattern
Moulding and Coremaking
provides outstanding casting surface quality.
Pre-filling
Using gravity to evenly feed and distribute lumpfree sand onto the entire surface of the pattern
provides outstanding casting surface quality
(fig. 2).
PHASE
PHASE11 --PREFILL
PREFILL
Outstanding casting skin quality
Outstanding casting skin quality
Possibility
Possibilityofofusing
usingfacing
facing -sand
-sand
Prefill ensures that clot -free sand always fill deep pockets
and cavities , even when the pattern contour is most intricate,
as is the case with this knuckle arm mold
The shooting phase
FRITZ HA NSB ER G S.p.A.
This is used to create high surface-compaction
of the mould by converting the kinetic energy The Shooting Phase
accumulated by the sand into a compaction
force, this provides a mould surface hardness Is used to create high surface compaction of the mould by converting the kinetic energy
right up to the flask walls (fig. 3).
accumulated by the sand into a compaction force, this provides a mould surface hardness right
High-pressure squeeze
Unmatched mold
up to the flask walls.
surface definition
Variable from 4 to 14 kg/cm2 provides the
vertical hardness component and mould rigidity
Fig. 2
4/10
(fig. 4). The advantages of high-density moulding
as opposed to conventional, jolt/squeeze can be
summarised as follows:
PHASE
PHASE22 -- SHOOT
SHOOT
• Reduced casting dimensional variation.
Excellent
Excellentmold
moldsurface
surfacehardness
hardnesswith
withhomogeneous
homogeneousdistribution
distribution
Closer casting dimensional tolerances are
from
frommold
moldcenter
centertotoflask
flaskedges
edges
achieved as a result of the dense, more tightly
NO need of venting on pattern and/or pattern plate
Distance
NO need of venting on pattern and/or pattern plate
packed moulds associated with high-density
to edge
… or LESS
25 mm...
moulding.
• Reduced casting mass variation. An overall
casting mass reduction up to 15% can be
expected when traditional, jolt/squeeze
Mold hardness
FRITZ
HA NSB ER G S.p.A.
machines are replaced with high-density
87-92°
+GF+
moulding machines.
• Improved casting surface finish. Higher
sand compaction against the pattern surface
enhances mould surface definition yielding
High Pressure Squeeze
Shooting is instrumental to
castings with improved skin quality.
achieving high compaction in
deep cavities where squeezing
Draft angle
• Improved pattern-plate surface utilisation.Variable from 4 to 14 Kg/Cm2 provides the vertical
hardness
component and
rigidity
0.5 mould
°
alone can
not always reach
The higher mould compaction associated with
high-density moulding reduces the distance
Fig. 3
between pattern and flask walls.
• Reduced pattern draft angle.
PHASE
• Reduced use of cores. Thanks to the higher
PHASE33 --SQUEEZE
SQUEEZE
sand compaction associated with highUniform
Thanks to the high Strictly controlled
Uniformcompaction
compactionthroughout
throughoutthe
themold
molddepth
depth
density moulding, higher cods and thinner
pressure squeeze
compression force
Minimum
phase, outstanding
per mold surface
Minimumcasting
castingmass
massvariation
variation
mould sections can be formed as part of the
mold rigidity is
unit (adjustable from
always achieved
4 to 14 kg /cm )
greensand moulds, which would otherwise
Minimum
usage
of
sand
–
NO
need
of
mold
strickling
Minimum usage of sand – NO need of mold strickling
require the use of chemically bonded sand
cores.
• Reduced noise emission. While Leq
(continuous equivalent noise pressure level
at operator position) values in excess of 100
dB(A) are normally associated with traditional
jolt/squeeze machines, high-density moulding
systems feature noise levels below 85 dB(A).
• Reduced maintenance. Because of the relevant
vibrations involved with jolting, massive
equipment and pattern wear is associated
5/10
with jolt/squeeze machines.
f
2
Fig. 4
Pattern and pattern-plate design
comparable to cast iron.
High-density moulding patterns can be
Pattern-plates are usually of cast-iron construction because of
manufactured in a variety of materials, including
the required rigidity (deformation tolerance ±0.06mm). Patternwood, brass, aluminium, resins, cast iron and
The advantages
of high-density
molding
as opposedfor
to the
conventional,
jolt/squeeze
molding
plate pins
and bushings
are responsible
accuracy of
flask/
steel. Pattern life ranges from about 1,000 cycles
can be summarized
as follows:
patternmaking,
and have a direct impact on the dimensional accuracy
for wooden patterns, to 300,000 cycles for cast
of the castings. The normally accepted clearance for each pin/bushing
iron and steel. High-density polyurethane resins
• assembly
Reducediscasting
dimensional variation. Closer casting dimensional tolerances
±0.06mm.
combine relatively low cost with performances
are achieved as a result of the dense, more tightly packed molds associated with
high-density molding.
FTJ September 2008
•
Reduced casting mass variation. An overall casting mass reduction233
up to 15%
can be expected when traditional, jolt/squeeze machines are replaced with highdensity molding machines.
Moulding and Coremaking
Pins and bushings are often fitted to the pattern-plate bolster or
carrier, but whenever strict casting dimensional accuracy is required,
they are fitted to the pattern-plate to allow for a rigid bolster design
and reduce clearance build-up.
On account of the high-pressure levels involved in the mouldmaking process, flask rigidity is of paramount importance in highdensity moulding. Flask design is usually based on finite element
analysis (FEA), a computer simulation technique whereby the
concerned part is assimilated to a geometrical model consisting of
a number of discrete (finite) elements linked on a grid or mesh. The
analysis allows accurate calculation of the stress and deformation
pattern under a given load.
Flask construction can be either fabricated steel or cast iron. In the
latter case, nodular iron, double-wall flask design combining high
rigidity with lightweight is normally preferred.
The moulding machine
Moulding machine design varies significantly reflecting the moulding
method employed by each manufacturer. Setting aside the distinctive
features deriving from the method employed, a common machine
classification rests on the ability to produce either cope or drag
moulds (single-station moulding machine), or both (double-station
moulding machine).
In turn, double-station moulding machines can be classified
depending on the way the cope and drag pattern-plates travel through
the machine; these include shuttle, rotary and
vertical-loop machines.
Most high-density moulding machines are part
of fully automatic facilities and include features
such as automatic pattern-plate changeover
facility; pattern heating facility and pattern blowoff facility.
The design of the flask handling system
is mainly dictated by requirements including
direction of sand supply flow; direction of metal
supply flow; direction of core supply flow;
direction of casting output flow; space available;
production rate and cooling time.
A typical automatic flask handling system
layout includes cope/drag flask turnover unit;
automatic sprue cutting unit; core setting line;
cope flask turnover unit; flask closing station;
transfer cars; pouring line; cooling line(s);
punch-out station; flask parting station and flask
cleaning unit.
Fritz Hansberg SpA. Tel: +39 (0) 0593 33488;
fax: +39 (0) 0593 33431; email: hansberg@tin.it
web:www.hansberg.com
UK office: Tel/fax: +44 (0) 1243 545363;
email: erniebartlett@foundryuk.freeserve.co.uk
Preparation of inorganically bonded core sand
The application of various
inorganic binders for cores was
tested in the foundry of a German
automobile manufacturer.
A mixer that had already been in operation in the
core shop was used for the preparation of the
core sand, problems being encountered in the
core shooting that resulted from inhomogeneous
mixtures. However, by using a Statormix core
sand mixer (fig. 1), designed and manufactured
by the German company Klein Anlagenbau AG,
these problems were solved.
Klein thoroughly tested the special twochamber mixing process of the Statormix with
inorganic binders, optimising it for this particular
kind of application.
Fig 1. The Statormix core sand mixer
234
By using this type of mixer the bending strength of one inorganic
binder, comprising three liquid components, could be increased from
the expected 400N/cm² to approximately 540N/cm² allowing the
binder dose to be reduced considerably. Core sand that is less moist
can be better processed in a core shooting machine, requiring less
drying. Fig. 2 illustrates the achieved bending strength in relation to
the added share of binder.
The suitability of the Statormix was also confirmed with inorganic
binders consisting of powdery components in the core shooting
process of several other foundries. The tightness of the two chamber
mixing drum and the very short mixing time contribute to reducing
loss of moisture of the mixed batch and thus loss of bending strength
of the produced cores.
Additionally, thanks to the integrated self-cleaning mechanism,
the mixer could be kept clean easily, demonstrating that inorganic
binders and the Statormix work well together.
Klein Anlagenbau AG. Tel: +49 (0) 2734 501 301; fax: +49 (0) 2734 501
327; email: buschhaus@klein-ag.de, info@klein-ag.de
web:www.klein-ag.de
Fig 2. Achieved bending strength in relation to binder share
FTJ September 2008
Moulding and Coremaking
Larger match plate moulding
machines launched
Introduced in 2001, the DISA
MATCH 130, match plate moulding
machine, has proved its worth for
shorter runs with frequent pattern
changes at foundries in four
continents.
Major reasons for the immediate success of the
machine range was a robust design that ensured
higher mould density, better accuracy with more
production flexibility for lower costs and higher
earnings.
‘With the DISA MATCH being an immediate
success’, says Kurt Larsen, general product
manager at DISA Industries A/S, ‘we spotted the
potential to help foundries by offering a solution
for match plates larger than 20x24 inches.’
The Benton Foundry in Pennsylvania, USA, was
the first to purchase the original DISA MATCH
and according to Benton’s president Jeff Hall, the
20x24 inch machine delivered superior mould
quality with harder, firmer and more consistent
moulds.
Because of the excellent experience with its first
DISA MATCH, when Benton Foundry was looking
for a larger match plate option, it decided to wait
for the introduction of the new larger unit. Delivery
of the new 28/32 machine is scheduled for August
2008.
Service-friendly with exceptional accuracy
When designing the new machine, the objective
was to make a robust and service-friendly unit
requiring minimum maintenance.
‘The most striking change is that there are
now two main guide rods instead of the original
four’, Kurt Larsen explains. ‘The symmetrical
construction, with centred guide rods without the
need for pins and bushes between the cope and
drag chamber, provides the rigidity for exceptional
mould accuracy giving a mismatch of less than
0.01”/0.25mm.’
Fast plate changes using the Quick Match
Plate Changer, combined with speeds of up to
100 uncored moulds and 80 cored moulds per
hour for the largest sizes (32”x32”/81x81cm),
provides foundries with a new level of flexibility
and performance. Independent adjustment of
cope and drag height on each mould half enables
optimisation of the iron/sand ratio as well as
reduction of sand consumption.
Combined with the new control system, these
features enable foundries to produce large
high-quality castings of different types more
FTJ September 2008
Benton Foundry was the first to purchase the original DISA MATCH
consistently and more cost-effectively.
A large access door and a wide access area inside the machine
with light curtain safety protection provide fast service access to
all components for easy maintenance. Another enhancement is
replaceable wear plates that can be changed very quickly without
disturbing other settings. In addition, an automatic system
lubricates the bearings during each cycle eliminating the need
to stop the machine for manual lubrication, ensuring maximum
uptime.
Full size range now available
The DISA MATCH New Platform is fully supported by
DISA Customer Service worldwide and is available in two
versions – Medium Platform with a chamber size of 24x28”
(61x71cm), and Large Platform with chamber sizes of 28x32”
(71x81cm) and 32x32” (81x81cm). The DISA MATCH 130
(20x24”/51x61cm)) is still available, DISA having a patent
pending on the DISA MATCH design.
More information is available from Kurt Larsen, general product
manager.
Tel: +45 (0) 44 50 50 50;
email: kurt.larsen@disagroup.com
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The fast loop making
moulds up to 3 x 1.8m
and 40tph mixer without
guarding in place
A partnership full of eastern promise
The accelerating rate of the recent growth in Indian
engineering technology has been well documented, a
prime example being the development of the machine
tool manufacturer, JYOTI CNC Automation Pvt Ltd.
The company was established in 1989, originally
to produce gearboxes, then lathe manufacture was
introduced and now a full range of CNC machine
tools is sold and distributed to many continents.
Jyoti has a large team of design engineers with
technical centres in Chennai, Rajkot and Pune,
the equipment supplied is covered by the ISO
9001:2000 certificate.
Until recently Jyoti obtained its requirements
for castings from the local foundry industry,
but in 2007 a complete new foundry was built
and commissioned to supply the high-quality
ductile iron components needed by the in-house
production plant.
The rollover stripping unit leaving the Omega premises – a
tight fit!
236
Following
preliminary
meetings between
Hydraulic mould manipulator with 7.5t capacity
Jyoti and Gargi
Engineering
Enterprises Pvt
12 complete moulds per hour,
Ltd of Mumbai, the basic
the furan sand is fed at the
requirements for the foundry
mixing station by a SPARTAN
were discussed with Omega
240A high-speed continuous
Foundry Machinery Ltd of
mixer. This has automatic
Peterborough, UK, who then
control of setting time and a
provided a full project design
six metre long primary arm that
and specification. The foundry
can also be used for making
was to be housed in the main
large moulds/cores in an area
building of 153 x 54 metres
at the side of the main loop. A
and would include moulding,
five tonne per hour mixer and
melting, fettling and inspection
compaction table is installed for
facilities.
the production of smaller cores.
The moulding station on the
Boxless moulding loop
loop has a compaction table
The building was completed
with a load capacity of 6,000kg
early in 2007 and the moulding
and after automatic strickle,
plant was installed later in the
the completed half-moulds
year. Mould production is based
pass through an eight-station
on a loop to produce boxless
automatic fast-loop before
moulds with dimensions of up
being fed to a rollover unit.
to 3,000mm x 1,800mm with a
After stripping the mould exits
maximum half-mould height of
and is fed into a rollover flood750mm.
coating unit.
The production rate is 8 to
The pattern is returned to the
FTJ September 2008
Moulding and Coremaking
moulding loop or to the pattern
change. A water-based paint is
used for the coating and this is
dried in a five-station gas-fired
convection oven.
Hydraulic mould
manipulator
transferred on to a 3.2 x 2.7
metre GAMMAMAJOR shakeout/
attrition unit for separation. The
sand is then fed to a 15 tonne/
hour sand reclamation plant,
which cools and classifies the
sand before being returned to
the hoppers above the mixer stations.
The moulding plant has quickly reached its
target production of quality castings to meet the
growing requirements of the Jyoti assembly plant.
For further information, contact Omega Foundry
Machinery Ltd, Peterborough UK.
email:sales@ofml.net or visit www.ofml.net
After core setting, the moulds
are closed using a beam-type
hydraulically operated mould
manipulator with a lift capacity
of 7,500kg. Using the same
manipulator, the closed moulds
are transferred on to an empty
pallet on the first of the five
pallet lines, each with a capacity
of 13 pallets, so a total of 65
pallets is in circulation. At each
end of the lines, a transfer car
moves the loaded pallets before
and after pouring.
After the appropriate cooling
time, a pallet is moved to
the push-off station where
the mould and casting are
The excess sand
is automatically
strickled off after
mould filling
For all your no-bake equipment needs
Omega Foundry Machinery Limited • 8 Stapledon Road • Orton Southgate • Peterborough • PE2 6TB • United Kingdom
Tel: +44 (0)1733 232231 • Fax:+44 (0)1733 237012 • web: www.ofml.net • email: sales@ofml.net
FTJ September 2008
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