Complete molding lines

Transport systems, tilters and manipulators for flask and flask molds, tumble dryers, knock out grills, regeneration and pneumatic transport systems, etc.
A complete casting site based on the Molding loop molding system (also known as Fast loop) allows castings to be manufactured in flask / flask molds of various sizes. The performance of the systems depends on the size of the molds and can reach 15 molds per hour.

 

TYPICAL SYSTEM OPERATIONS:

1. CHANGE OF MODEL EQUIPMENT

The shift of model equipment provides easy access to equipment for cleaning, preparation and maintenance operations. The plot can be connected to an automatic computerized warehouse for storage of equipment.

 

2. FORMATION

To fill the form, continuous mixers of the required performance are used.

 

3. REMOVAL OF EXTRA MIXTURE

At the filling position, the mixture is compacted using a vibrating table. The table can be adjusted to various shaking intensities, depending on the required characteristics of the mold to be made. An automatic knife is used to remove the rest of the mixture.

 

4. CURE FORM

The forming section includes a number of mold curing positions.
The half-molds are alternately transferred to the curing position on the transport plates. Each half-form is transmitted independently of the others using a special transport device. Such a scheme allows you to speed up or slow down operations, depending on existing operating conditions.

 

5. TURNING AND DRAWING FORM

The extraction section of the model is fully automated, operations are performed using the edge device. After this, the form is transferred for painting, the model plate is returned to the molding section. If the model is not extracted the first time, the canting mechanism automatically repeats the operations of extracting the model.

 

6. PAINT FORM

The painting operation is simplified by the use of stations at which the form is moved by the manipulator to the position most convenient for the used painting method.

 

7. DRYING FORM

Depending on the colors used, different drying mechanisms are used. Alcohol-based paints are conventionally dried by firing at positions equipped with exhaust ventilation, while water-based paints require the use of drying ovens. In some cases, if drying of the mold is required before painting, an additional dryer is installed in front of the painting station.

 

8. INSTALLATION OF RODS

The rod alignment conveyor provides easy access to the half-molds for rod alignment.

 

9. ASSEMBLY OF FORMS

a. Manual
Depending on the duration of the work cycle, the mold can be assembled semi-automatically or manually. In the first case, manipulators suspended from a working crane are used to assemble the forms. In the second case, operations are performed on a fixed station using a lifting device that is controlled by the operator.

b. Automatic
For high-performance lines, the assembly of forms is automatic. The automatic device performs all the operations for the assembly of forms without the participation of the operator, regardless of the size of the assembled forms.

 

10. FILLING FORMS

At the assembly position, the molds are mounted on pallets, on which they are then fed to the pouring area. After pouring, the molds can be placed on the cooling section, where they can be installed either directly on the floor, or on a two-tier cooling rack, or in a vertical mold storage.

 

11. KICK

After cooling, the molds are transferred to the knockout area. The site can be equipped with either a vibrating grid or a dividing tunnel. The separated mixture enters the regeneration system, after which it can be reused.

 

12. REMOVAL OF CASTINGS

Castings can be removed manually, using a bridge crane or using manipulators equipped with a dustproof, air-conditioned cabin, which provides the best working conditions for the operator.

 

13. SYSTEM MANAGEMENT CABINETS

The electrical control system complies with the most modern world standards and is designed taking into account the most modern technologies. The system uses programmable logic controllers of the models most common around the world, which allows you to operate automation systems known to the technical staff of the Customer.

 

CHARACTERISTIC FEATURES OF THE SYSTEM:

- The molding and chemical hardening systems of the Molding loop series make it possible to realize the best application of the most modern binding materials, even those that are characterized by extremely low survivability. In molding loop systems, individual operations are performed independently of each other. This allows you to reduce the total cycle time for a single form, while adapting the production for the application of various model options.
- The production layout is quite arbitrary, which allows us to adapt the system in accordance with the individual requirements of the Customer.
- The modular concept used by Sogemi also allows the rational use of existing production facilities.
- The degree of automation can be selected at the request of the Customer, depending on technological requirements.
- The molding section includes three main areas: mold preparation, molding and model extraction. These zones are connected by transport devices, each of which works independently to transfer model plates to the nearest free area for subsequent operations. It is possible to simultaneously produce molds according to 6-8 models of various types and sizes.

 

If you need advice on the application or on the purchase of complete molding lines for XTS processes in Ukraine, please contact Kitmas specialists.