Measuring where it really matters - Michenfelder

draft report for trade press publication in the magazine GIESSEREI ERFAHRUNGSAUSTAUSCH 11/2008
Measuring where it really matters
Moulding sand management system FoMaSys improves productivity and pays
for itself fast. Well-known foundries throughout the world rely on FoMaSys with
which manufacturer MICHENFELDER has established his special process
technological solutions to keep moulding sand quality constant on highest level
Authors: Manfred Michenfelder, Christoph Huck
Pictures: Michenfelder
FoMaSys
Module 1 Module 2
SPEEDMULLOR
BMD
Moisture Control
Systems for Sand
Coolers
Moisture Control Systems for Mixers
G+F
EIRICH
....as well as mixers from Küttner,
Disa, Simpson, Technical, Graue,
Stotz, Savelli etc.
Module 3
Fig_1:
Precise sand moisture thanks to continuous measurement in the
mixer
A network of cleverly integrated
single moisture control and sand
testing modules ensures constant
high-quality moulding sand
properties directly at the moulding
machine. That way, moulding sand
production becomes more effective
by considerable reduction of scrap
rate.
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 switched
over to fast moulding lines, and
moulding sand production has
switched over to high performance
mixers, mostly fitted with coolers. But
the drop in the quality of sand and the
moisture content
On-line Sand
Testing System
VEDIMAT
Module 4
Process Control
System MiPro
KÜNKEL-WAGNER
Patent pended mixing
dynamic control
On-line monitoring of moisture
content and degree of homogenization
of each batch from mixer charging to
discharging
mixing time
Moisture Control
Systems for
Mixers
increase in scrap are in direct
proportion to the reduction in sand
capacity and in the increasing
frequency of cycle and regeneration
times in sand bunkers. In modern
foundries, the quality of sand is
suffering from ever faster mixer and
moulding machine cycle times,
enormous thermal loading as a result
of 24/6 or 24/7 production, frequent
model changes, major fluctuations in
sand-metal ratios and an ineffective
and variable addition and yield of
additives and superfines. This has
resulted in changes in the composition
and homogeneity of the sand with
major repercussions for mechanical
properties of the sand such as
compactability, compression strength
etc.
Best moulding sand quality for
outstanding casting results
Efficient casting involves more than
fast mixing and moulding. Moulding
sand properties of consistently high
FoMaSys
Module 1
Module 2
Module 3
On-line Sand
Testing System
VEDIMAT
Module 4
Process Control
System MiPro
Moisture Control System for Coolers
installation example
Temperature probe
with evaluation unit
stick electrode with
protective cap
kit with solenoid and
motor-driven valves
Measurement transmitter
optimised water addition
Fig_2:
Consistently high moisture levels of at least 2.0% H2O at the cooler
outlet is important for outstanding sand quality in downstream
processes
quality are a crucial factor for
satisfactory casting and a low volume
of scrap. This conclusion has finally
been accepted and has forced
foundries to address the issue.
An integrated network for a
complete chain of control
Many foundries are often totally
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. Such a concept is FoMaSys
from MICHENFELDER.

draft report for trade press publication in the magazine GIESSEREI ERFAHRUNGSAUSTAUSCH 11/2008
FoMaSys
Module 1
Module 2
Module 3 Moisture Control
Systems for
Mixers
Moisture Control
Systems for
Coolers
Online Sand Testing System VEDIMAT
Material taking from con-
veyor belt by elevating unit
test of compactability
charging of test cylinder
test of compressive strength
Fig_3:
By controlling compactability at the moulding line directly, any
subtle changes are detected and compensated for through
feedback to the moisture control system. That means
compactability is automatically kept very constant.
The idea behind FoMaSys
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, the motto is: What comes
out should be the same as what goes
in – i.e. it should be as consistent as
possible concerning times and
quantities. Measurement and control
technology ensures that first of all, the
sand is accurately pre-wetted (to at
least 2%) in the used sand bunker, and
secondly, that it reaches the moulding
line with consistently optimal
mechanical properties (flowable).This
ensures the reliability of the tried and
trusted moisture measuring and control
systems that are networked and
monitored centrally. The high level of
automation also produces
rationalisation effects. Precision and
reliability reduce scrap, and continuous
control ensures a sand conditioning
process that is cost-effective and that
consistently conserves resources.
Constant compactability where it
really matters – directly at the
moulding line
As a relevant factor for sand quality,
online control of compactability is
essential. Automatically controlling
compactability through the addition of
water during production has become
an established trend. In order to obtain
Module 4
Process Control
System MiPro
installation example
Moisture Control
Systems for
Mixers
or expand the relevant expertise,
competitors have now responded by
entering into joint ventures and
acquisitions. In the case of some
manufacturers, this expertise has
been developed in-house over several
years – one-stop system solutions, as
demonstrated so convincingly by the
FoMaSys are a matter of course.
More and more imitators are coming
to the realisation that continuous
measurement in the mixing equipment
(i.e. in the mixer or cooler) is essential
for a precise sand moisture control. In
relation to this major issue, FoMaSys
manufacturer Michenfelder can rely on
a head start of 40 years of knowledge.
Success factors
1.) The sand moisture is kept
constant within a tight tolerance
of 2% at the cooler outlet.
2.) The incomparable precision of
moisture measurement and mois-
ture control achieved thanks to
the accurate in-mixer and incooler
measurement technology
(incl. the patented mixing
dynamics monitoring system)
3.) The special installation location of
the online sand testing system
VEDIMAT on the conveyor belt
directly before the moulding machine.
Module 1
Module 2
Module 3
Moisture Control
Systems for
Coolers
FoMaSys
Module 4
Process Control
and Quality Assurance System MiPro
Total plant view
Materialaufnahme vom
Förderband per Aufzug
On-line Sand
Testing System
VEDIMAT
Process data analysis, evaluation
Einbaubeispiel
and archiving
Monitoring of single modules remote control in 1-to-1-view
Fig_4:
With MiPro moulding sand quality control comes into your office.
Analyse the trends and evaluate production data – online or from
archived database. Make relationships and developments in the
sand cycle transparent comprehensible in an easy way.
By combining FoMaSys modules 1 and
3, it is possible to reliably record and
compensate for any negative factors
influencing the moulding sand on its
way from the mixer to the moulding
machine that could have a long-term
detrimental impact on compactability
(e.g. different bentonite saturation
levels due to unstable initial moisture
in the mixer, or moisture changes due
to differences in temperature, and
evaporation or mechanical changes
caused by aeration or material transfer
stations). None of these influences are
identified or taken into account when
compactability is measured in the
mixer. Variations of ±0.1% in moisture
levels in the mixer result in
compactability fluctuations of up to ±2-
3% in the moulding machine. There
are some foundries where fluctuations
of up to 10-12% in compactability
between the mixer and the moulding
machine have been shown to occur –
particularly when there is no sand
cooler at all or where there is a sand
cooler in which sand moisture is poorly
regulated.
From a well-nursed prejudice to
technological head start
However, there is one preconception
that needs to be eliminated: contrary to
what many people believe or claim to
be the case, measuring compactability
just before the moulding machine is by
no means too late. Since it is well
known that there is a correlation
between moisture and compactability,

FINAL MOISTURE reliability and high precision
thanks to MICOMP UNI for measurement in mixers and coolers
COMPACTABILITY
CENTRAL CONTROL
R
draft report for trade press publication in the magazin GIESSEREI ERFAHRUNGSAUSTAUSCH 11/2008
the exact precision of the moisture
measurement and control system
MICOMP UNI Type G-CH incorporated
in the mixer ensures that as soon as it
leaves the mixer, the moulding sand
has a very constant moisture content
and therefore consistent
compactability. The downstream
VEDIMAT now ensures that even the
slightest changes in compactability
caused by a steady but slow change in
the sand composition (and not by
moisture) are detected and that,
through feedback to the MICOMP UNI,
they are reliably compensated for by
minuscule adjustments to the amount
of water required (to fractions of a
hundred in some instances).
Fast amortisation as most important
investment incentive
Depending on the technical priorities
fully automated consistency
thanks to the special installation
positioning of the VEDIMAT and feedback to moisture control system
O I
eturn n nvestment
and the available budget, the various
FoMaSys modules can be installed in
graduated steps over several years.
The design consists of a fully
automated moisture measurement
and control system for mixers
(module 1), coolers (module 2),
conveyor belts, drums linked to online
sand-testing systems (module 3) that
are placed directly before the
moulding line (and deliberately not at
the mixer). Finally, MiPro (module 4)
makes the sand cycle transparent,
connections and correlations 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. This is proven by successful
FoMaSys projects throughout the
world.
Germany:
Eisenwerk Brühl in Brühl, Georg
Fischer in Leipzig, Buderus in Limburg,
SLR in St. Leon-Rot
Europe:
Skoda in the Czech Republic, the
Componenta Group in Finland,
Nannoka Vulkanus in the Netherlands,
Odlewnie Polskie in Poland, Fytasa
Fundiciones in Spain,
Overseas:
Mahle in Brazil, Weichai Power in
China
Current project planning:
SLR Elsterheide in Germany, Arabian
Axles in Saudi Arabia, Danaven in
Venezuela, the JSC-Group in Russia,
Radijator in Serbien, WHB in Brasilien
all major sand parameters centrally
and online under control with MiPro
and if things go wrong, we provide Internet support
nvestment
fast amortisation thanks to reduction in
sand-related scrap and improvements in sand-quality
FoMaSys
The Moulding Sand Management System
MICHENFELDER ELEKTROTECHNIK
An der Fahrt 4, 55124 Mainz/Germany
www.michenfelder.com
info@michenfelder.com
TEL.: +49-(0)6131-91017-0 / FAX: -17
Systematic Moulding Sand Preparation
from shake-out grid to moulding machine