CPT International 01/2019
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The common heat applications in<br />
the core box are the use of thermo oil<br />
and heating rod while additional heat<br />
energy is applied to the core via heated<br />
air while removing humidity.<br />
The key problem remains: sand<br />
(cores) heat conductivity is terrible. As<br />
a consequence the core box is operated<br />
with excessive heat to increase the<br />
heat transfer into the sand core with<br />
the aim to reduce the cycle time. This<br />
approach has limitations as the sand<br />
binders have a maximum temperature<br />
to avoid damaging the chemical binder.<br />
The „Advanced Core Solutions<br />
“(ACS) project has patented a new process<br />
that generates the heat directly<br />
inside the sand core. This process uses<br />
the electrical conductivity of the inorganic<br />
binders. Heat is generated by<br />
applying electrical current to the sand<br />
core.<br />
The core box design is very simple<br />
as it mainly contains the core box, electrodes<br />
and isolation layer as visible on<br />
the picture below. The obvious benefits<br />
of reduced energy consumption<br />
Individual measurement of energy consumption<br />
with ACS technology.<br />
and better sand core quality due to<br />
homogeneous curing of the full sand<br />
core are enriched by the underlying<br />
possibilities to control the quality per<br />
individual sand core.<br />
The flow of electrical current<br />
through the sand core is at ever millisecond<br />
controlled and documented. This<br />
allows to measure the energy<br />
consumption, temperature and time<br />
per individual sand core even in larger<br />
core boxes with multiple cavities.<br />
Furthermore can the quality data<br />
be linked to each sand core and used<br />
Photo: ACS<br />
for life cycle tracking. This enables<br />
future insights by applying big data<br />
analysis by connecting the results to<br />
final foundry product quality.<br />
The true potential comes in play if<br />
the individual sand core results are<br />
compared to all previously manufactured<br />
sand cores.<br />
Using the Six Sigma concepts allows<br />
now to detect any major variation versus<br />
previous results and sand cores can<br />
be marked for additional inspections<br />
or removal. This decreases quality<br />
defects early in the manufacturing process<br />
to reduce additional losses later in<br />
the manufacturing steps and at the<br />
same time increasing the output capacity.<br />
The technology especially becomes<br />
interesting for large sand cores or sand<br />
cores with high annual volume. The<br />
estimated benefits reach up to 30%<br />
faster curing processes without shell<br />
formation and at the same time reduce<br />
33% energy consumption due to elimination<br />
of external heat generation.<br />
https://advanced-core-solutions.de<br />
KNOW<br />
YOUR<br />
SAND.<br />
EFFICIENT FOUNDRIES<br />
KNOW THAT WHAT GETS<br />
MEASURED GETS<br />
CONTROLLED.<br />
More foundries around the world<br />
choose Simpson Analytics for their<br />
sand lab than any other<br />
technology. Consisting of over 85<br />
instruments,<br />
Simpson Analytics is:<br />
• More flexible to different<br />
standards<br />
• More accurate<br />
• More repeatable<br />
• Easier to use<br />
• More durable<br />
• Easier to calibrate<br />
Simpson Analytics, including all<br />
of the former +GF+ products, is<br />
supported by our global service<br />
network, based in the USA,<br />
Germany and India, for spare<br />
parts, repair and calibration.<br />
VISIT OUR ONLINE RESOURCE CENTER TO IDENTIFY THE RIGHT TECHNOLOGY FOR YOUR<br />
FOUNDRY AT WWW.SIMPSONGROUP.COM/SAND<br />
HALL 17<br />
STAND B60<br />
Simpson Technologies (Deutschland) GmbH<br />
Roitzheimer Strasse 180, 53879, Euskirchen, Germany
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