Presentation on theme: "Modulated machine design"— Presentation transcript:
1Modulated machine design for core production with inorganic binders
2Inorganic binders Main Advantages Emission and odor free for humanity and environment,Compliance with future environmental laws,Reduction of casting failures caused by core gas,Condensate deposit on the mould drop or rather decrease significantly, thereby increase in productivity and cost reduction in the maintenance,Decoring ability due to adjustable water soluability,Reduction of disposal costs of the used sand,Cost savings in the field of exhaust technique and scrubbersHigher uptimes of core boxes based on lower cleaning timeEtc.2
3Inorganic binders are inert Organic binders burnInorganic binders are inert3
4Inorganic binderOrganic binders burn, condensates contaminates the moldWith inorganic binders the mold is clean4
5Basic Facts Characteristics of inorganic binders Hardening physically and chemicallyMostly physical instead of chemical reactionCharacteristics in machine engineeringOpportunity to heat toolingsOpportunity for hot air flushing5
8Challenges and Solutions Avoid dry and hardening of core sand in the shooting nozzles due to dry and hot ambient atmosphere.↓Solutions:Cooling of the shoot plate and the nozzles as know from hotbox system or shell core.Problem:In difference to hotbox systems wherein hardening starts by temperature only, inorganic system will dry out at the nozzles‘ tip even when cooling the nozzle.Moisturing of the ambient area around these shooting nozzles by water spray.Water droplets will condensate at the cool nozzles, water droplets wash away binder skin from the sand grains and cause defects in the core surface and body.Water not to be sprayed in as droplets but as cold vapor. The evaporation of the water will be done by ultra sonic generator (system patended by Laempe).8
9Technical SolutionsUltra sonic vaporing of shooting nozzles9
10Technical SolutionsUltra sonic vaporing of shooting nozzles10
11Challenges and Solutions Avoid dry and hardening of core sand in the sand hopper above the machine and in the shooting unit after the shot.↓Solutions:Moisturing of the air above the sand level by water spray and covering of the hopper top.Problem:Water droplets will condensate at the cool nozzles, water droplets wash away binder skin from the sand grains and cause defects in the core surface and body.Water not to be sprayed in as droplets but as cold vapor. The evaporation of the water will be done by ultra sonic generator (system patended by Laempe).11
12Kernschießmaschinentechnik SolutionKernschießmaschinentechnikUltra sonic vaporing of shooting unit
13Kernschießmaschinentechnik SolutionKernschießmaschinentechnikUltra sonic vaporing of shooting unit
14Kernschießmaschinentechnik SolutionKernschießmaschinentechnikUltra sonic vaporing of shooting unit
15Kernschießmaschinentechnik Challenges and SolutionsKernschießmaschinentechnikChallenge:Due to the lower floability of certain binders and depending to the design of the shoot plate, sand channels may be formed in the shooting system.↓Solutions:Using of a „bridge breaker“(system patended by Laempe).Side effect:Using the bridge breaker will also deliver informations about the sand level in the shooting unit and so optimize sand dosing – even under such conditions where conventional optical systems will not work.Forming of „sand channels“
16Kernschießmaschinentechnik Challenges and SolutionsKernschießmaschinentechnikChallenge:(Most) Inorganic binders require warm or hot coreboxes. Coreboxes need to be heated up to 200°C (392°F)Heating methodsAdvantagesDisadvantageselectrical heating by conventional resistance heatersknown technology from hotbox technologyeasy to operateaccurate temperature controleasy tool designing, especially if separate heater plates are usedOnly middle-rate heat transferheater cardrigdes reduce freedom of tool design;efficiency of the heat transfer is depending to tool accuracyfor big toolings energy transfer requires big cablesThermo transfer oilgood heat transferknown technology from high pressure casting processtool design unusual for coreboxes due to liquid channelscomplex piping system requiredSteamexellent heat transferReduced piping system required compared to oil heatingHigh energy densitymostly unknown technology to pattern makers and operatorshot steam under high pressure
17Kernschießmaschinentechnik Challenges and SolutionsKernschießmaschinentechnikTest equipment:Specially adapted coreshooter type LBB1010 l shooting volumeEquipped to operated all known binder processesMixer directly installed above sand shutterUltra sonic moisturing system for shooting system and shoot plate
18Kernschießmaschinentechnik Challenges and SolutionsKernschießmaschinentechnikHeating equipment:Oil temperature unit make ROBOMAT and steam generator make CERTUSS.Both systems with heating capacity of 30 kW.
19Kernschießmaschinentechnik Challenges and SolutionsKernschießmaschinentechnikComparisson of piping system:Oil pipes with supply line and back line for each circuit.Steam system with supply line for each circuit and common back line.
20Not only for inorganic bonded cores… Special SolutionsNot only for inorganic bonded cores…Challenge:Identification of castings in relation to core production data, like shift, binder or sand batch, etc. even after batch-independent core storage.↓Solutions:Marking the cores by an ink printer directly after production and engraving a code by laser into the sand core.
21Kernbearbeitung – Lasern/Bedrucken Special SolutionsKernbearbeitung – Lasern/Bedrucken
22Contact Thank you for your attention! Laempe & Mössner GmbH Let‘s work together to keep our world for the next generations.Laempe & Mössner GmbHTel: (0) 7622 / 680 0Fax: +49 (0) 7622 /Laempe & Mössner GmbHSchopfheimGrienmatt 32D Schopfheim22