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TABLE OF CONTENTS Example Sand preparation plant 4 Plant Concept Designs 6 Automatic Water Dosing for shake out drums/Cooling drums FRS-T 7 Automatic used sand pre-moisturising FRS-A 11 Automatic Moisture Control at the Cooler/Continuous Mixer FRS-K 15 Automatic Moisture Control at the Batch Mixer FRS-M 19 Description capacitive Humidity measurement at the Batch Mixer 23 Automatic Sand Testing Systems SPC 25 Example Sand cooling / Moisture boost 29 Pneumatic Binder Injection BMI 30 Water Dosing Equipment DF 1010 41 Conveyer belt scale 43 Questionnaire plant Concept Designs 46 Questionnaire Moisture...

Example Sand preparation plant

Controlled pre-moistursing on belt applications Moisture control systems on cooler and continuous mixer Continuous weighing Level control Continuous level control Hopper scales for used sand and additives FORMSANDMANAGEMENT SYSTEM Sand Process Controler for the detection of: Compactibility Shear-strength Compression-strength Bulk density Temperature Moisture Water dosing on tubes and tanks Moisture control systems on batch mixer 5

plant ConCEpt dESignS

innoVatiVE plant ConCEpt dESignS automatiC watEr For ShaKE out drumS / Cooling drumS • moisture measurement • temperature measurement • material flow • water flow Follow us on social media: Social icon Rounded square Only use blue and/or white. For more details check out our Brand Guideline

watEr doSing For ShaKE out / Cooling drumS The task of shake out and cooling drums is to separate sand and castings and to cool simultaneously. Mould blocks are fed into the drum and are disintegrated by means of vibrations or rotation. The sand drops through openings onto a used sand conveyor belt, while the castings are leaving at the drum end and are transferred to the fettling shop. The movement inside the drum effects a heat exchange and the water in the sand evaporates partly, contributing to lowering the sand temperature. For improving the cooling effect on castings and sand, a demand-oriented,...

HARDWARE As a module for connection to the FRS-Central or as a single version with its own HMI in a control cabinet. In the case of PLC-based control and control units, a selection between a Siemens S7 or a PLC from the company B & R industrial electronics is possible (as of May 2019). It is also possible to adapt to existing older PLC versions. SOFTWARE • Multi-touch menues • Presentation of the process data • Intuitive user interface • Measuring watchdog function DATA BASE All process-relevant data are filed in a data base and presented graphically for evaluation. In addition to the control...

THE COOLING EFFICIENCY IS INFLUENCED BY THE FOLLOWING BOUNDARY CONDITIONS: • The water absorption capacity of the air depends on temperature • The sand to castings ratio • The shape and the movement of castings in the drum • Temperature distribution in the mould block can vary extremely It should be kept in mind that over-wetting of the sand can cause sticking and blocking of the sieves and result in increased lump formation, hampering separation of castings and sand. In case of insufficient moisturising the desired exit temperature of castings and sand is not reached, which is of disadvantage...

innoVatiVE plant ConCEpt dESignS automatiC uSEd Sand prE-moiSturiSing inCrEaSing EFFiCiEnCY through EarlY moiStEning • moisture measurement • temperature measurement • material flow • water flow Follow us on social media: Social icon Rounded square Only use blue and/or white. For more details check out our Brand Guidelines

uSEd Sand prE-moiSturiSing Every foundryman working with bentonite-bonded sand is looking to have a reliable moulding material of sufficient form properties, covering a wide product range and allowing the production of perfect castings. The cost of after-treatment should be kept low, just as the energy consumption in the fettling shop and, in the worst case, the energy consumption for remelting defective castings. In addition to our well-known and proved moisture control systems at coolers, cooling drums and mixers, automatic sand testing systems for compactibility and other optional properties...

HARDWARE As a module for connection to the FRS-Central or as a single version with its own HMI in a control cabinet. In the case of PLC-based control and control units, a selection between a Siemens S7 or a PLC from the company B & R industrial electronics is possible (as of May 2019). It is also possible to adapt to existing older PLC versions. SOFTWARE • Multi-touch menues • Presentation of the process data • Intuitive user interface • Measuring watchdog function DATA BASE All process-relevant data are filed in a data base and presented graphically for evaluation. In addition to the control...

The result is a well-moisturised und cooled mould material which can regenerate in the hoppers and which for the next cycle can be finished in the mixer with a „final“ amount of water. Moulding materials with temperatures above +50 °C in the mixer are difficult to condition and are the source of defective moulds and, consequently, of sand-related casting defects. It is therefore essential to install reliable industry-proved sensors for determination of the used sand values „Residual moisture“ and „Temperature“ at suitable points. Just as important is the determination of the throughput per time...

innoVatiVE plant ConCEpt dESignS automatiC moiSturE at thE CoolEr / ContinuouS mixEr • Moisture measurement greensand • Temperature measurement greensand • Material flow • Water flow • Moisture measurement air • Temperature measurement air Follow us on social media: Social icon Rounded square Only use blue and/or white. For more details check out our Brand Guidel

moiSturE Control at thE CoolEr / ContinuouS mixEr By implementing of moulding sand coolers the used sand is to be primarily cooled down effectively after shake out. A further very important objective is to pre-moisturise the used sand for initiating and accelerating the regeneration of the used sand in the hoppers prior to the further conditioning cycle. To achieve this objective, a constant sand moisture in the range of approximately 1.8 to 2.5 %, depending on sand type, should be aimed at. With all cooler types the evaporation cooling principle if used. Example fluid bed cooler: The cooling...