Efficient, lean production with seamless automation
DISA and Wheelabrator worked together to select exactly the right equipment to match Dianzhan’s specifications, with every workflow planned for maximum, automated efficiency. The entire production line runs automatically and continuously, from sand preparation and iron melting through to moulding, pouring, shake-out and blasting. Every work area and piece of equipment is seamlessly and automatically coordinated with its neighbouring process and the moulding line.
This neatly-packaged, integrated complete green sand solution for the foundry has a compact layout, minimising the distance between all the different foundry process stages. This translates into reduced manpower requirements, shorter distances for materials to move – and no need for forklifts in the plant area. The space saved also leaves room for other equipment to be installed in future. The sand plant employs DISA’s classic double cooling drum design combined with a high-efficiency control module. With consistent sand quality and the minimal distance between sand production and the moulding line, moulding sand can be prepared and used only when needed by the moulding line.
Perfectly matched plant – and dust-free too
The DISAMATIC D3 vertical moulding machine lies at the heart of the moulding line and combines high speed with exceptional yield and quality. Throughput is blisteringly fast: up to 485 moulds per hour with core setting and 555 moulds per hour without, all with a mould misalignment of less than 0.01 mm. After cooling and shake-out, Wheelabrator’s DT14-450 rocker-barrel-type shot blasting machine cleans the castings by gently tumbling parts in through-feed operation. Fully automated like the rest of the production equipment and working continuously, its small footprint helps it fit easily onto the tightly-packed factory floor. DT shot blast machines require no loading or unloading and cope easily with changing parts, types or volumes.
Shot blasting operations are dust-free, like all the new foundry’s work areas. Part of the integrated complete green sand solution, the design embraces every piece of plant to effectively improve overall dust removal performance and helps Dianzhan meet the increasingly stringent environmental requirements facing iron foundries. Condensation is a major challenge in dust removal: if not handled in time, it can easily paralyse the production line. The integrated plant design tackles condensation at every stage of the casting process. For example, DISA’s new heating furnace employs heating and insulation treatment within the parts of the sand treatment system with high levels of moisture.