michenfelder elektrotechnik

BEST
MOULDING SAND QUALITY
FOR BEST CASTING RESULTS
FoMaSys
The Moulding Sand Management System
MICOMP UNI � for uniform moisture content in mixer + cooler
VEDIMA T � for constancy in compactability + mechanical properties
MiPro � central process control + key role in balancing consumption
Keep fully under control all significant moulding sand
parameters from shake-out grid to moulding machine
MICHENFELDER ELEKTROTECHNIK
An der Fahrt 4, 55124 Mainz/Germany
www.michenfelder.com
info@michenfelder.com
TEL.: +49-(0)6131-91017-0 / FAX: -17

New challenges – New approaches
Just a few years ago, the cycle times were long, the sand bunker capacity was large and the
throughput of sand per shift was low i.e. the best requirements for satisfactory moulding sand
conditioning. This leisurely pace is now a thing of the distant past. By investing millions, the
manufacture of high quality cast products has been switched to fast moulding lines, and moulding
sand production has been switched to high performance mixers, mostly fitted with coolers. But just as
sand capacity, cycle times and regeneration times in sand bunkers were reduced, the quality of sand
dropped and scrappage increased. In modern foundries, the quality of sand is suffering as a result of
ever faster mixer and moulding machine cycle times, frequent model changes, serious fluctuations in
sand-metal-ratios and an ineffective and inconstant addition and extraction of additives and
superfines. This has resulted in changes in the composition and homogeneity of the sand, with major
repercussions for the mechanical properties of the sand such as compactability, compression
strength etc.
Best moulding sand quality for best casting results
Efficient casting involves more than fast mixing and moulding. Consistently high quality moulding
sand properties are a crucial factor for satisfactory casting and a low volume of scrappage. This
conclusion has finally been accepted and needs to be addressed.
A new approach
Many foundries are often unaware of the problem. This permanent thermal loading of the sand
requires a basic change in strategy with regard to moulding sand conditioning – i.e. adopting an
integrated approach. Leaving behind the stand-alone measuring technology solutions applied in
recent years and adopting a concept that will allow for the careful re-instatement of moulding sand
quality, from the shake-out grid to the moulding machine, using cleverly integrated measurement and
control systems.
The idea behind FoMaSys
Fast amortisation guaranteed
Depending on the technical priorities and the available budget, the various FoMaSys modules can be
installed in graduated steps for years to come. The design consists of a fully automatic moisture
measurement and control system for mixers, coolers, conveyor belts, drums linked to online sandtesting
systems that are placed directly in front of the moulding line (and deliberately not at the
mixer). Ultimately, MiPro makes the sand cycle transparent, connections and correlation become
clearer and you have full online control over all the important sand parameters. Never before has an
investment in a moulding sand conditioning process paid for itself so quickly. It has been proven by
successful international FoMaSys projects.
FoMaSys
The Moulding Sand Management System
The idea behind FoMaSys is to create a network of intelligent measurement, control and testing
systems, while at the same time trying to combat the effects of dehomogenisation and change by the
application of process technology. Looking at additives and superfines, that means: Times and
quantities of extraction and addition processes should be as equal and consistent as possible.
Measurement and control technology ensures that first of all, the sand is reliably pre-wetted (with at
least 2.0% H 2O) before it reaches the used sand bunker, and secondly, that it then reaches the
moulding line with consistently optimum mechanical properties (flowable). This is achieved by using
the tried and tested Michenfelder moisture measurement and sand testing systems which are
networked and monitored centrally. The high level of automation produces rationalisation effects.
Precision and reliability reduce scrappage, and continuous quality control ensures a sand
conditioning process that is cost-effective and that consistently conserves resources.
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
MOULDING SAND MANAGEMENT SYSTEM

Moulding sand moisturising system Type LC
Solution for moisture measurement and control in accordance with the common principle of
measurement on conveyor belts and in balances
MICHENFELDER ELEKTROTECHNIK
An der Fahrt 4, 55124 Mainz/Germany
www.michenfelder.com
info@michenfelder.com
TEL.: +49-(0)6131-91017-0 / FAX: -17

We can facilitate a price comparison
To allow you to make a fair comparison, we have decided to expand our product range to include
the low-cost moulding sand moisturising system LC. It is the alternative to competitors’ systems
available in the market. The moisture probe is installed on the belt upstream of or in the used sand
weighing device. This facilitates a true price comparison.
Scope of delivery
The LC system consists of a self-cleaning NF-SR moisture probe. The measurement generator and
the processing unit are located in the separate steel-plate housing. The moisture values measured
in Volt and the evaluated material temperature in oC are transmitted to the processing unit for
conversion to a percentage moisture value. Forty years of experience at Michenfelder have gone
into this data conversion process. The system has been designed for installation and
commissioning by the customer. To facilitate this, we supply a CD ROM with commissioning report,
program flow visualisation and instructions for the adjustment of the characteristic curve using the
customer’s PC or laptop.
Operating principle
When commissioning is complete (when the calibration value curve has been drawn up), the NF-
SR probe measures the initial material moisture. The integrated processing unit then calculates the
volume of residual water to be added depending on the batch size. At the same time as the used
sand flows into the mixer (filling process), the calculated water volume is automatically metered out
to the required final moisture level that was preset.
The principle of measuring moisture upstream of the mixer
With regard to hardware technology and the measuring point upstream of the mixer, the LC system
provides you with the same kind of solution as that offered by the competitors. If you are about to
make this investment decision, you must remember that when measuring material on the belt or in
the used sand bunker, in principle, only part of the volume of material in a full mixer batch can be
recorded. This means that the accuracy of the initial moisture with reference to the entire batch is
only an average max. of ± 0.2% H2O (in the 1st standard deviation). Depending on the clay
content, this can result in variations of up to ± 5-10% in compactability at the moulding machine
directly. This is common to all systems that measure moisture upstream of the mixer.
Who is the LC system designed for?
There are customers who, for financial or other reasons, cannot or do not wish to exploit the full
potential for reducing the moulding sand related scrappage in their production system by improving
moulding sand quality. In cases such as this, customers are chiefly concerned with improving sand
preparation processes in the areas of mixing, moulding and casting generally. Therefore, if the
primary motivation is to avoid “extreme outliers” in the area of moulding sand moisture that can
frequently result in production stoppages, then the installation of the low-cost moulding sand
moisturising system is a suitable alternative.
Given the growing requirements in modern foundries, investments must be quickly
amortised, i.e. they must pay for themselves. This is best achieved by fully exploiting all the
optimisation potential provided by measurement and control technology in order to reduce
scrappage in a sand preparation plant. For this, we recommend Michenfelder’s modular
Moulding Sand Management System FoMaSys.

Future-proof
and
cost-effective
from the
start
MICOMP UNI
The fully automatic moisture control system
type G-CH
for batch mixers
FoMaSys-Modul
FoMaSys-Module
No other decision to invest in measurement and control can have more
far-reaching consequences in the field of modern moulding sand
conditioning. It is a trend-setting system. If decisions are reached on the
basis of technical priorities, precision, future development and
expansion capabilities, and amortisation periods, the MICOMP UNI type
G-CH is a must - regardless of whether an existing mixer is being
modernised or a new green-field foundry is being established.
Mastery of this technology is what has made a difference – for more
than 30 years. Only through measurement in the mixer is the
incomparably high reproducibility of the output moisture within very
strict limits guaranteed. Since all the moulding sand components
such as sand, bentonite, C-carriers and water only come together in
the mixer, it is only there that a representative and precise
determination of moisture can be made. This is the only way to
achieve precise values of ±0.05 – 0.1% H 2O in the 1 st standard
deviation over shifts, days and weeks.
The patented
mixing dynamic
monitoring
system
Continuous
measurement
of moisture in
the mixer
This is used to get the maximum out of your mixer – without losing
valuable time. The sand moisture in the mixer is constantly
monitored, from the time material is charged until the moment of
discharging. The total homogenisation and conditioning degree for
each individual batch is displayed graphically in real time. This allows
the operator to draw conclusions regarding the mixing dynamic, i.e.
the performance capabilities of the mixer. The advantage: It is
possible to prevent scrappage as a result of a drop in mixer
performance and to optimise process steps such as the addition of
water and material.
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
AUTOMATIC MOISTURE CONTROL SYSTEM FOR MIXERS

An
investment
that quickly
pays for
itself!
Why does it
actually
need to be so
precise?
MICOMP UNI
The fully automatic moisture control system
type G-CH
for batch mixers
Is there any more convincing argument? Place your trust in the
technology of the market leader and you will find out. You prefer to
base your investment decision on facts – no problem either:
� Hundreds of success stories regarding its use in all kinds of
moulding sand mixers throughout the world
� Maximum precision and reliable at every phase of production
� Versatile software and hardware expansion options
� Achievable precision of ±0.05 -0.1% H 2O*
*(in the 1 st standard deviation)
� As a basic FoMaSys module, it is designed for expansion
and networking with the VEDIMAT online sand testing
system (for constant compactability) and the central
process control system MiPro
FoMaSys-Module
As a criterion for good casting quality, there is a greater emphasis
than ever on constant mechanical sand parameters (e.g.
compactability). The same applies to moisture content as a
corrective element. But did you know that fluctuations of just one
tenth at the mixer outlet can have a direct influence on
compactability of up to 2-3% on the moulding line? No? Well
now you know why the precision of moisture measurement and
control systems needs to be measured in hundredths.
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
AUTOMATIC MOISTURE CONTROL SYSTEM FOR MIXERS

Where does the
compactability of your
sand need to be
constant?
The success factors – Part 1
VEDIMAT
The fully automatic online sand-testing system
Do you measure the compactability values in the
laboratory or at the mixer only? If that is the case, then
you are wasting an opportunity to improve your casting
quality and reduce scrappage. The VEDIMAT controls
and regulates compactability and measures the
compression strength directly in front of the moulding
machine because this is the point at which the quality
of your moulding sand should be at its peak.
� The ideal place for installation
Keeping compactability constant at the mixer is not very helpful. This does not
identify or take cognisance of negative factors that affect the sand when it is
being transported to the moulding machine. A combination of the VEDIMAT and
the MICOMP UNI type G-CH systems reliably registers and compensates for
these changes (e.g. fluctuations in temperature, evaporation and bentonite
saturation effects) so that constant, high quality mechanical sand properties are
achieved at the point where they are really needed – on the moulding line.
� Networking a high-precision moisture measurement and control system
As a compactability correction factor, sand moisture is a very important issue.
Moisture fluctuations of one tenth at the mixer outlet can have a direct influence
on compactability amounting to ±2-3% on the moulding line. So if you want to
keep compactability constant within a narrow band, you need a moisture
measurement and control system that measures and controls precisely within a
few hundredths.
FoMaSys-Module
FoMaSys-Modul
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
ONLINE SAND-TESTING SYSTEM

The success factors – Part 2
VEDIMAT
The fully automatic online sand-testing system
However, compactability is not affected by moisture
alone. The sand composition and the bentonite
saturation level are also crucial factors.
Reducing costs by minimising scrappage
The conceptual approach and technological implementation are crucial factors in relation to a
successful outcome and whether the investment will be worth your while. Take a bet on the
perfect combination of the two independent FoMaSys components, the VEDIMAT and the
MICOMP UNI type G-CH.
FoMaSys-Module
FoMaSys-Modul
� Identifying changes and taking gentle counter-action – before run into trouble
The sand composition (i.e. the ratio of new, used and core sand, C-carriers, bentonite and
other superfines) is permanently changing. In principle, the constant adjustment of the water
requirement to the changing sand composition during the production process ensures that
compactability automatically remains constant. By taking simple attendant measures, you
yourself can further improve the level of precision. Ensure a constant composition and
homogeneous distribution of the sand components by avoiding sudden, irregular additions
during the sand cycle. Do your sand an enormous favour and act as follows with effort: Times
and quantities of extraction and addition processes should be as equal and consistent as
possible.
� Avoid stress
Short cycle times, high throughput and extreme, constant thermal loading place enormous
stress on your moulding sand. There is barely enough time left for regeneration in bunkers, or
there is not enough moisture in the bunkers to disperse the bentonite (at least 1.8-2.0%). If the
sand fed to the mixer is too dry, full bentonite saturation is often not achieved before it leaves
again the mixer. This results in major compactability fluctuations. And what can you do about
it? Commence regeneration and conditioning early! Ideally in the cooler.
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
ONLINE SAND-TESTING SYSTEM

Sand conditioning reliability starts
in the cooler
1.8-2.0% H2O
T h e c r i t i c a l f a c t o r
Breath life
into your
moulding
sand
MICOMP UNI
The fully automatic moisture control system for
type G-MC/G-91/G-FBK
mixer coolers and fluidised bed coolers
Even at the cooler and used sand bunker, the die for high casting quality and
minimum scrappage at the moulding line has been cast. Fast mixers, a high
throughput, short cycle and bunker storage times are a real challenge when it
comes to manufacturing high quality moulding sand. However, tough general
conditions and a soft, flowable, well-conditioned moulding sand are not
mutually exclusive – providing the right processing technology and
measurement and control systems are used.
If the used sand moisture at the cooler outlet is below the critical level of 1.8-2.0% H 20,
regeneration cannot take place in the used sand bunker. The active bentonite content
does not disperse. The sand remains static and lifeless. Valuable regeneration time is lost
and cannot be clawed back at a later stage in the mixer. There is then just barely enough
mixing time to homogenise the aggregates, but hardly for satisfactory conditioning. The
result: When it gets to the moulding line, dispersion processes have not been
completed, the sand is not flowable, the mechanical sand properties are not constant and
your scrappage levels are correspondingly high.
Kill at least two birds with one stone
Not only do you lay the foundation for flowable moulding sand, satisfactory casting and low scrappage levels
when your used sand moisture levels are sufficiently high. There is also another highly beneficial by-product
when it comes to your conditioning process. You provide support for your sand mixer and the loading is
massively reduced. Unlike in the case of dry sand, the sand mixer can intermix the required amount of water
homogeneously into the well pre-wetted sand much more quickly. In this way you can gain valuable conditioning
time, save on energy and reduce wear and tear.
Precise to the n th
degree – and no
need to worry about
over-wetting
If you want to reduce stress levels for yourself and your sand, integrate
a precise and reliable moisture measurement and control system into
your cooler. With the MICOMP UNI, achieving the critical limit values is
child’s play and there is no need to worry about over-wetting and
clogging up bunkers, conveyor belts and bucket elevators. Completely
automatically – on Monday mornings, after every break and after a 100
hours of production.
FoMaSys-Module
FoMaSys-Modul
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
AUTOMATIC MOISTURE CONTROL SYSTEM FOR COOLERS

MICOMP UNI type G-MC
(alternative type G-91)
the moisture control
system for mixer coolers
�
�
�
�
�
MICOMP UNI
The fully automatic moisture control system for
type G-MC/G-91/G-FBK
mixer coolers and fluidised bed coolers
When you make a decision,
choose the market leader!
Over 500 mixer coolers throughout the world have been fitted
with Michenfelder systems. Well-known manufacturers of
mixer coolers have regularly placed their trust in them over the
past number of years
Only by measuring in the cooler, is a high-precision, reliable
output moisture content guaranteed. Initial temperature and
moisture fluctuations are successfully compensated for in
every phase of production
Freely adjustable moisture value, moisture display in % H 2O directly (type G-MC)
Versatile software and hardware expansion options available (type G-MC)
Practical expansion of the FoMaSys moulding sand management system
MICOMP UNI type G-FBK
the moisture control system for fluidised bed coolers
Fluidised bed and/or vibration cooler users are familiar with the problem of serious output moisture fluctuations.
Moisture control that is purely temperature-dependent is not a suitable solution. There are too many situations
that you cannot control. For example, no water is added to cold, dry sand and what’s worse, the exhaust system
also extracts the loose character-forming superfines (the typical “Monday problem”). The sand becomes
inhomogeneous. Cold and unpoured sand is not identified either. The sand becomes too wet, resulting in
problems
.
on the conveyor belt, in bunkers and in bucket elevators. For fear of over-wetting, there is a temptation
to operate at a too dry level from the fluidised bed cooler, with all the problems this entails for subsequent
conditioning. If you choose the leading technology in the form of the MICOMP UNI type G-FBK, you will get
constant moisture at the fluidised bed cooler outlet at every phase of production. The interaction of precision
measurement technology (moisture probes and temperature gauges) and optimum water addition (valve and
nozzle kits) will be the major factor in your success.
� Reference projects are proof of success and cost-effectiveness
� Achievable precision of ±0.1 -0.2% H 2O (in the 1 st standard deviation)
� Freely adjustable moisture value, moisture display in % H 2O directly
� Versatile software and hardware expansion options
� Practical expansion of the FoMaSys moulding sand management system
FoMaSys-Module
FoMaSys-Modul
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
AUTOMATIC MOISTURE CONTROL SYSTEM FOR COOLERS

MiPro
The central process control,
data analysis, archiving and
quality assurance system
More than just another
screen in the control room
MiPro is much more than the sum of its individual functions. As a combined modular software/hardware
system, it carries out process control, data evaluation and archiving, visualisation and quality assurance tasks
so that it quickly becomes an integral part in the development of a centrally managed moulding sand cycle.
With MiPro, sand conditioning
comes into your office
Everything under control, CENTRALLY and ONLINE
By networking the various technical measurement and control sub-systems in the plant to MiPro, you can
control and monitor moulding sand quality from a central point in real time. All the most important information
streams in from the integrated moisture measurement and sand testing systems. You operate all the systems in
1 to 1 optics, just as if you were standing in front of the relevant machine. Your conditioning hardware (coolers,
mixers, containers, conveyor belts) is visualised individually so that you can find your way around immediately
and feel comfortable operating it.
What happened last week? Who changed what, when and how? How did the clay
content effect compactability and water need yesterday?
That is just a fraction of the questions that MiPro can answer. MiPro quickly becomes an essential tool for your
short and long-term data archiving, with a number of comfortable statistical analysis functions, an alarm control
management system, a system for assigning rights in order to protect unauthorised access and intrusions, and
much more besides.
Making new findings useful for the production processes of tomorrow
Identify trends and negative developments, volumes and consumption and use these as a basis for making the
right decisions for the production of tomorrow!
Identifying and understanding interrelationships
With MiPro, interrelationships and correlation can be displayed transparently and in a comprehensible way in
real time for the first time – a prerequisite for optimisation measures that are even more far-reaching.
FoMaSys-Module
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
CENTRAL PROCESS CONTROL AND QUALITY ASSURANCE SYSTEM

MiPro
The central process control,
data analysis, archiving and
quality assurance system
Additives – as much as required
as little as possible
With its computing power, MiPro expands the potential of the VEDIMAT online
sand testing system. Its measurement values serve as a basis for determining the
clay content in moulding sand. Information regarding changing trends in the
bentonite content facilitate strategic corrections and thereby an efficient use of
bentonite that saves on resources.
More than just a trend – early used sand
regeneration Create the conditions for well-conditioned and flowable moulding sand as early as
possible in the sand cycle. The foundry manager is familiar with model-specific
burn out losses. The challenge is to return sand quickly, efficiently and
strategically in the correct volumes after the casting process on the basis of a
flask tracking system. Michenfelder and MiPro can offer you assistance with this.
MiPro pays for itself faster than you might imagine
Even the first negative development or inconsistency detected by MiPro will justify
the investment. Would you like an example? The increase in scrappage rates
experienced by a customer regularly resulted in a reduction in casting quality on
the moulding line at a certain point in the production process. With MiPro, it was
possible to prove that a drastic increase in the superfines content, caused by
adding the collected dust all at once, was responsible for the problem. The dust
recirculation was rearranged (what comes out should be re-added in same
quantity and within same time window) and the problem was solved. This specific
reduction in scrappage paid for the investment in MiPro in one fell swoop.
FoMaSys-Module
Michenfelder Elektrotechnik GmbH & Co. KG
info@michenfelder.com | www.michenfelder.com
CENTRAL PROCESS CONTROL AND QUALITY ASSURANCE SYSTEM