automatic modular casting line type bav multi-stick ... - Azienda in fiera

AUTOMATIC MODULAR CASTING LINE TYPE BAV MULTI-STICK M10/3 FOR STICK-ON RIM BOWLS.
( THE MACHINE IS READY TO WORK EVEN WITH SPAGLESS SYSTEM TECHNOLOGY)
Every casting unit (10 moulds line capacity) is composed of:
1) Supporting steel structure bolted an welded constituted of:
- 1 base structures in welded beams profiles;
- 2 couples of columns in steel welded rectangular profiles;
- 1 top “bridges” structure made with a couple of beam NPU welded profiles;
- 1 intermediate “bridges” structure made in squared welded profiles 120mm;
- 1 lower “bridges” structure made in squared welded profiles 120 mm complete of 10 couples of hinges
UPN80 profile equipped with radial bearings and steel seats;
- 10 sets of steel clamps for lateral moulds assembling;
- 02 steel support carpentries for movable chain conveyors and for suspended chain conveyors;
- n.10 steel hinged frames for rim moulds installation fabricated in CNP100 welded steel profiles:
- n.10 steel adjustable bases for rim moulds;
2) Transmission system constituted of:
Vertical motion:
- Nr. 01 motor gear boxes 3 KW with frequency drive (orthogonal axis type);
- Nr. 02 right angle boxes;
- Nr. 02 end-less screws TPN60 x 9 mm. (right & left execution)
complete of bronze volute;
- Nr. 02 linear motion systems with bearings;
Horizontal motion:
- Nr. 01 motor gear boxes 1,5 KW (end-less screw type);
- Nr. 05 couples of end-less screws TPN30 (right & left) complete of bronze volute and mounted on
mechanical couplings.
- Nr. 05 linear motion systems with bearings;
2 Couples of chain conveyors motion (10 pieces line):
- Nr. 02 + 02 motor gear boxes 1,5 KW/each (longitudinal motion);
- Nr. 04 motor gear boxes 0,25 kW/each provided of centralized frequency

controller (lateral motion for de-moulding);
3) Casting circuit (10 moulds line) constituted of:
a) Bodies Section
- 2 branches of PVC flanged pipe diam. 120 mm.(10 mt.) and diam. 63 mm.;
- 10 clamp saddles 120mm x ¾”;
- 10 ball manual valves diam. ¾” complete of hose nipples;
- 2 plastic slip level tanks 30 lt. Capacity;
- 2 electro-mechanical slip level controls;
- 03+03 pneumatic valves complete of position magnetic sensors (2 each one);
- 02 manual ball valves diam. 2”
- Set of silicon rubber pipe for slip feeding to the moulds;
b) Rims section
- 2 branches of PVC flanged pipe diam. 120 mm.(10 mt.) and diam. 63 mm.;
- 10 clamp saddles 120mm x ¾”;
- 10 ball manual valves diam. ¾” complete of hose nipples;
- 2 plastic slip level tanks 30 lt. Capacity;
- 2 electro-mechanical slip level controls;
- 03+03 pneumatic valves complete of position magnetic sensors (2 each one);
- 02 manual ball valves diam. 2”
- Set of silicon rubber pipe for slip feeding to the moulds;
4) Drainage circuit (10 moulds line) constituted of:
a) Bodies Section
- 01 air blower (low pressure) for slip drainage complete of filter;
- 2 branches of PVC flanged pipe diam. diam. 63 mm.(32 mt.);
- 10 clamp saddles 63mm x ½”;
- 10 ball manual valves diam. ½”complete of hose nipples;
- 02 over pressure mechanical valves diam. 1” ½;
- 02 pneumatic ball valves diam. 2” complete of position magnetic sensors (2 each one);
- 01 pneumatic pump diam. 2” (slip recovery);
b) Rims section
- 01 air blower (low pressure) for slip drainage complete of filter;
- 2 branches of PVC flanged pipe diam. diam. 63 mm.(32 mt.);
- 10 clamp saddles 63mm x ½”;
- 10 ball manual valves diam. ½”complete of hose nipples;
- 02 over pressure mechanical valves diam. 1” ½;
- 02 pneumatic ball valves diam. 2” complete of position magnetic sensors (2 each one);
-
5) N. 10 axial fans diam. 300 mm.
220/380V 50Hz. – installed power 150W
6) Compressed air circuit (30 moulds line) constituted of:
- 01 Centralized electro-pneumatic panel (3 casting units) including;
- 01 air filter regulation group diam. 1” (0 – 7 bars);
- 06 air pressure regulators diam. ½”; (0-7 bars);
- 03 double solenoid 5/2 electric-valve ½” 24VAC (double effect pneumatic cylinder for lower
moulds sliding);
- 12 solenoid pilot electric valve 5/2 1/8” 24 VAC (pneumatic activated valves DN50 Main slip
feeding) complete of distributor and accessories;

- 06 double solenoid 5/2 electric-valve ½” 24VAC (double effect pneumatic cylinders for lockage
of rims moulds metal frames);
- 06 double solenoid 5/2 electric-valve ½” 24VAC (double effect pneumatic springs for individual
closing of rims moulds);
- 06 double solenoid 5/2 electric-valve ½” 24VAC (double effect pneumatic springs for individual
closing of bodies moulds);
- 06 double solenoid 5/2 electric-valve ½” 24VAC (double effect pneumatic cylinders for individual
sloping of rims moulds);
- 03 double solenoid 5/2 electric-valve ½” 24VAC (double effect pneumatic compact pressing
devices for individual closing of lateral sides moulds);
- 03 on/off electric valve diam. ½” for actioning pneumatic pump for slip recovery;
- Mufflers and accessories;
- 06 Pneumatic guns complete of spiral pipeline L=32 mt.;
- 60 pneumatic springs (short - run) 40 mm. for bodies moulds vertical closing system (single
pressing system);
- 60 pneumatic springs (short - run) 40 mm. for rims moulds vertical closing system (single
pressing system);
- 60 pneumatic devices (short - run) – for lateral moulds closing system (single pressing system);
- Set of accessories and plastic flexible pipe for connections;
- n.30 double effect pneumatic cylinders (short run) for steel frames blockage during casting
process (rims moulds);
- n.30 double effect pneumatic cylinders for rim sloping during slip drainage phase;
- 09 solenoid pilot electric valve 5/2 1/8” 24 VAC (pneumatic activated valves DN50 - fast drying
and de-watering process) complete of distributor and accessories;
-
7) Painted steel pipes for compressed air distribution to the casting moulds (fast drying and dewatering
process) complete of automatic three ways valves, distributors, manual valves,
connections, compressed air regulation group and accessories. N.03 different circuits and pipelines.
8) Hydraulic safety devices against suspended structures falling. The system is composed with 2
pistons equipped of integrated flow control devices and out-let electric signal.
9) Centralized electric control board dim. 2800 x 400 x 2000 mm. (3 casting units) constituted of:
It should control the following motors:
- 03 by 3 kW/each (central casting unit – lifting moulds);
- 03 by 1,5 kW/each (central casting unit – opening lateral moulds)
- 06 by 1,5 kW/each (air blowers for slip drainage)
- 12 by 1,5 kW/each (deposit belt conveyors – longitudinal motion)
- 12 by 0,25 kW/each (deposit belt conveyors – lateral motion)
- 30 axial fans diam. 300 mm.
- 220/380V 50Hz. – installed power 150W
Should be controlled the following equipment:
- 42 solenoid electric pilot valves 5/2 diam. 24V AC;
- 03 on/off electric valve diam. ½” 24VAC;
- 12 pressure switches;
- 12 magnetic sensors for chain conveyor sliding removable guides;
- 18 limit switches for vertical motion control;
- 06 limit switches for horizontal motion control (moulds opening);
- 24 limit switches for lateral motion of chain conveyors;
- 06 electric limit switches (conveyors for transport pieces control);

- PLC with CPU dimensioned to control the above listed equipment;
- 12 electric level controls;
- 60 magnetic sensors for feed-back signal of pneumatic cylinders (rims moulds sloping);
- 120 magnetic sensors for feed-back signal of pneumatic cylinders (blockage of rims moulds steel
frames);
- 06 magnetic sensors for feed-back signal of pneumatic cylinder (rims moulds lower cars sliding);
- Touch screen operating panel 10” with synoptic panel;
- Nbr. 02 Additional remote touch screen panels 10”
- Software for automatic control of the following working phases:
- slip circulation for pipes cleaning;
- moulds closing;
- moulds filling (Slip Casting);
- slip drainage;
- hardening;
- moulds opening;
- de-moulding;
- start/stop spag-less moulds fast de-watering system;
- pieces transport on the belt conveyors;
- safeties;
(Control cabinet will be provided of lamp and acoustic alarm.)
General control board is realized in according with CE Standard Norms.
SEMI AUTOMATIC MULTI-LEVEL TRANSFER SYSTEMS MOD. TMP (Optional)
It is designed to work in synchronized way with the double level chain conveyor.
It is composed of:
- welded, bolted and painted steel frame (base + vertical columns) realised in squared
profiles and wheeled base;
- conveying movable table (LxW 1800 x 500 mm.) complete of driven chain
and motorization 0,25 Kw with frequency
drive;

- vertical high precision linear guides complete of wheels and movable car;
- motor gear box 0,75 kW. for vertical motion complete of electric brake and frequency controller for
soft start/stop. An encoder device is applied to this gear box in order to manage in automatic way
the multi-level deposit of the green pieces;
- vertical transmission system composed of 2 chains, pinions, forced expansion taper lock, steel
shaft and bearings and protection carters;
- longitudinal motion motor gear box 0,55 kW. equipped with frequency controller for soft start/stop
complete of pinion and 1,5 mt. of rack-over with shaped rail;
- compact electric box with human interface device “touch screen” assembled on adjustable
movable arm;
- electric power control board 800x400 mm. complete of mini PLC;
WORKING SEQUENCE DESCRIPTION:
- conveying movable table in lower standing position;
- automatic positioning on pick-.up level;
- starting of chain motion on transfer table;
- start of chain conveyor and transfer of casted piece on the movable table;
- automatic stop of chain motion on transfer table by means of limit switch;
- lifting of transfer table in correspondence to 2 nd level storage conveyor;
- contemporary starting of conveying motions on the transfer table and the 2 nd level conveyor to
operate drop off of casted piece.
- Automatic stop of conveying motions by means of limit switches;
- Automatic return of transfer table on the pick-up position to repeat the sequence;
MACHINERY TECHNICAL DESCRIPTION
001 - TECHNICAL DATA
-
Lenght
Width
Height
OVERALL DIMENSIONS (1 casting unit 10 moulds capacity):
10.660 mm.
7.905 mm.
3.930 mm.

-
Occupied surface
Approx. 85 sq.m.
TECHNICAL CHARACTERISTICS (1 casting unit 10 moulds capacity):
Production capacity
10 pieces/cast
Nbr. Cast/day 2 (**) 4-6 (***)
Casted pieces per day 20(**) 40-60(***)
Nbr. of workers
01/shift
Installed electric power
16 kW
Compressed air pressure
7 bars
Installed moulds 10
Type of production
Stick-on rims Bowls
(**) Increasable with a forced drying system mounted on the casting line
(***) with spagless system in 24 hours depending by the complexity of the casted items;
-
-
OVERALL DIMENSIONS (3 casting unit 30 moulds capacity):
Lenght
31.980 mm.
Width
7.905 mm.
Height
3.930 mm.
Occupied surface
Approx. 255 sq.m.
TECHNICAL CHARACTERISTICS (3 casting unit 30 moulds capacity):
Production capacity
30 pieces/cast
Nbr. Cast/day 2 (**) 4-6 (***)
Casted pieces per day 60(**) 120-180(***)
Nbr. of workers
01/shift
Installed electric power
16 kW
Compressed air pressure
7 bars
Installed moulds 30
Type of production
Stick-on rims Bowls
(**) Increasable with a forced drying system mounted on the casting line
(***) with spagless system in 24 hours depending by the complexity of the casted items;
MAIN GUARANTEED ADVANTAGES
1) Motorized opening/closing of all the moulds simultaneously;
2) Simultaneous de-moulding of all the casted pieces (same hardening level of the green products);
3) Simultaneous rims sticking;
4) Perfect closing of the moulds thanks to the single pressing combined system (mechanical/pneumatic);
5) Possibility to cast different models and designs in the same line;

6) Automatic casting;
7) Option of modular conception (10 by 10 moulds) of casting, drainage, hardening and moulds opening;
8) Longer life of moulds thanks to mechanized and controlled motions;
9) Easy drying of all the installed moulds thanks to the exploded standing position;
10) Limited deformation of the de-moulded pieces thanks to the absence of manual manipulation;
11) Low physical efforts of the worker;
12) Utilizable with spag-less system moulds;