CPT International 01/2015

AUTOMATION
Figure 3: Disa 270-A ventilated brake disc casting cluster
Average power consumption
in kW
ant role for many years. Until now discussions
have focused on reducing energy
consumption in the melting shop
where consumption is highest. While
the molding section may “only” account
for about 8 to 12 % of the total
production [1], there is still a significant
Connected load in
kVA
Disa 231 55 85
Disa 231 fast 60 85
Disa 240 75 105
Disa 250 90 145
Disa 270 110 155
Table 2: Electrical power consumption of Disamatic molding lines
savings potential to be found. Molding
shop energy consumption is split between
the sand plant and the molding
line. Depending on the type of molding
technology installed, the molding line
will account for between 30 and 55 %
of molding shop energy consumption.
Systematic use of robust vertical
molding lines based on lightweight design
criteria reduces energy consumption
significantly (Table 2). Here, too, it
is a good idea to address the average annual
consumption based on kWh per
ton of net castings. The drive for increased
efficiency demands working in
three shift production. Here we can set
off annual production hours and actual
energy consumption of the molding
line (molding machine, core setter, as
well as the pouring and cooling lines)
against net production showing a definite
potential for a consumption of less
than 10 kWh/t.
Given this result, Disa has nothing
to fear when comparing the Disamatic
vertical molding process with other
molding processes and energy consumption
is only about 20% of that of
flask lines.
The production of brake discs and
brake drums requires the highest possible
capacity at the lowest possible cost
– and thereby Lowering your cost per
casting. The Disamatic molding process
fulfils these requirements more
than any other. The machine design is
simple and robust and requires at most
only two additional main drives: one
for the molding machine and the other
for the pouring and cooling lines. Vertical
parting of molds enables placement
of the gating system, as well as venting
of the mold cavities, in the parting line.
Other systems or sources of disturbances
such as venting and drilling
devices (normal in flask molding) are
not necessary. Production normally re-
Single index Double index I Double index II
Amount of brake discs per mold 4 4 4
Brake disc diameter in mm 270 270
270
Weight per brake disc in kg 8,5 8,5
8,5
Pouring time in sec 10,4 13,3
13,3
Pouring speed in kg/sec ~4,5 ~3,5 ~4,5
Yield in % ~79 ~82,5
~79
Weight of the cluster in kg ~ 43,0 ~41,2
~43
Necessary melting capacity t/h ~12,5 ~13,3
~15,9
Brake discs per hour 1160 1288
1480
Use of energy for molding line kWh/t 12,4 10,0
9,7
Density of production t/m 2 ~95 ~105 ~120
Table 3: Example of the performance increase of a Disa 270-A using the double index
16 Casting Plant & Technology 1/2015