Moulding lines are standard equipment in modern foundries. The lines
produce large numbers of precision moulds with high levels of repeatability,
requiring a minimum number of operators.
The central components of a normal moulding line are the moulding machine,
the pouring and cooling line and the mould emptying station. The moulds
are produced automatically. All lifting, turning and feed movements are
integrated into the operating cycle of the line. Manual intervention
is reduced to a minimum.
The emptied and cleaned moulding flasks are entered into the moulding lines in pairs, and after careful checking of the outside contours and contact faces, fed into the machine. The required quantity of sand is brought forward after weighing and using an arrangement of pivoted flaps, evenly distributed in the mould. For compacting by means of the air flow, a hydraulically controlled SEIATSU valve is opened. Final compaction is achieved by means of a hydraulic press with flat or flexible pressure plate, water cushion or a multi-punch press. Pattern change carriages can be moved either manually or automatically, and assist in the rapid replacement of complete pattern units.
The mould halves are turned after leaving the machine in such a way that the mould face is upwards. Cores are inserted into the drag box, and vent hole pouring spouts are pierced into the cope box and the back of the mould. After turning the cope box back the other way, the mould is closed and taken in the normal way on a line carriage through the pouring and cooling zones. After the mould has been filled and cooled, it reaches the emptying station. Here, the sand pack, together with the casting, will be ejected and transferred to a separating channel. Sand remnants are removed from the flask, which is then returned to the moulding line.
This logic based system of automatic mould production is repeated in
all imaginable combinations. The decisive factor in the design of the
moulding line is the moulding machine itself, as the cycle time of the
moulding line will depend on this machine.
Advantages of hws Moulding Lines
Modern moulding lines are able to produce even small batches economically,
since the pattern change can be completed within the cycle time of the
line. It is possible to accommodate different moulding sands, different
flask heights and different metals all within a single line. The parameters
for the manufacture of the moulds, such as quantity of sand, compacting
pressure and compacting time, are stored in programmes selected on the
basis of model identification. The programme also controls the position
of the pouring funnel and venting holes, and controls the movement of
the mould in the cooling zone. Cooling times can be varied and it is
possible to follow each mould on its way up to the unloading station
on the VDU. Computers monitor the line, report the current operating
condition, produce protocol documents and localise faults.
Whilst economics remain the basic consideration for the purchasing of a moulding line, humane working conditions in the workplace and the environment must also be taken into considerations in making investment decisions.
The decisive factor in the assessment of the moulding line is the productivity achieved with the moulding process. Since 1983 hws have exclusively employed the SEIATSU Moulding process in order to produce dimensionally accurate moulds at a high order of reproducibility. The process minimises pattern wear and functions in an environmentally friendly manner.
hws moulding lines are in every detail matched to the rough surroundings of the foundry. Fully proven designs are fabricated and assembled in our own workshops. Bought-out components for hydraulics, electrics and elektronics are selected from reliable suppliers. hws moulding lines ensure high levels of availability and long working life, provided they are carefully and correctly maintained.
