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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
Page 1: BEST MOULDING SAND QUALITY FOR BEST
Page 5 and 6: Future-proof and cost-effective fro
Page 7 and 8: Where does the compactability of yo
Page 9 and 10: Sand conditioning reliability start
Page 11 and 12: MiPro The central process control,

michenfelder elektrotechnik

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