Foundry plants

Services for foundry and metallurgical industry

Within a team dedicated to work closely with the customer’s requests, WSS provides a full range of services for the design and automation of foundries, with a particular attention to the production process.

Continuous mixers

High-speed continuous mixers, single or articulated-arm, variable height discharge, mobile mixers, for all No-Bake processes from 3 to 60 t/h sand delivery. Binder flow and sand heating control systems
Mixers single arm WSS MS
Mixers with articulated arms WSS MD
Mixers with adjustable height WSS MDB
Mixers with translating single arm WSS MST
Mobile mixers WSS MMS-MMD
  • Mixing tank

    The mixing arm has a frame structure supporting two half shells, which form the mixing tube. These are split lengthways and are hinged at a single point behind the sand inlet. This opening arrangement gives easy access to the mixing shaft and blades for maintenance and cleaning. The mixing tube may be fitted with a removable wear lining. It has a mixer shaft with removable/interchangeable forged steel blades with tungsten carbide plates on every wear face.

  • First Arm

    In the mixers fitted with an articulated arm, the first arm consists of a structure which has a high speed transport belt. This enables the type of sand being fed, to be changed rapidly. Pneumatically controlled sand gates enable the sand supply to be controlled accurately. Simply pressing one button the system is able to change the type of sand, the rate of sand and choose different mixing of the sand.

  • Binder Circuits

    Our renewed system allows us to inject immediately the binders in the mixing trough, without using a recycle-system circuit. The advantage of our circuit is that the pump will have a longer lifespan. The injectors have been designed with an air injection assist which guarantees an excellent degree of atomisation of the binder fluids and keeps the injectors clean. The metering pumps enable the feed rates to be varied according to the chemical system being used. They are controlled by individual variators or inverters, according to the application. They guarantee the required metering precision and assure repeatable results.

  • Optional

     

      AUTOCAT 1

      The AUTOCAT 1 is a software to set the sand hardening times. The program controls the catalyst dosing with different reactivity in the mixing process. The catalyst dosage is regulated in according to the temperature of the sands. The operator can change the catalyst quantity using the graphic information displayed on the screen electric panel.


      AUTOCAT 2

      The AUTOCAT 2 software is a program for set the sand hardening times. The program operates on the dosing of two catalyst type, «strong» and «weak», with different reactivity during the mixing process. The catalyst dosage is regulated in according to te temperature of the sands and to the working area. The AUTOCAT 2 calculation program dose the quantity of catalyst in according to the reactivity caracteristics of the forming process, so that the sum of the flow rates of teh two fluids is aleays constant at the predeterminated fixed value according to the resin flow rate. The operator, thanks to the display on the electical panel, displays a indicative graph ot the catalyst dosage, and he can operate by changing the sensibility of the system to the temperature variation, for the calculation of the catalyst ratio «weak/Strong».


      Tanks

      Tank with cavity for heating water conditioning. The resin’s temperature is kept constant by a resistence, controlled by a thermostat that heats the water into the cavity.


      AFP - AUTO FLOW PUMP

      The AFP software is a program that guarantees a costant flow of binders for the preparation of the sand mixture, according to the value set by the user, thanks to the operator panel. The flow rate constancy is guaranteed by an automatic speed adjustment system of the pump, this system is in continuous loop with signal feedback from the flow meters for the instantaneous measurement of the flow rate of each agglomerating circuit. The system provides for the control of the functioning of the dosing fluids of agglomerating fluids with alarm thresholds for any malfunctions, which could compromise the preparation quality of the sand mixture.


      Auto batching pump

      The ABP software program allows the pumps to be calibrated and in the same time the amuont of liquid required for each program automatically. Thaks to a scale with special container, the system is able to create the pump flow curve and automatically it’s able to identify the pump speed for the amount of liquid required for each program. Also, the system serves to indentify the pump wear and to ceck the replacement time. On the operator panel will be a page with the pump curve and its setting.


      Auto batching pump + capacity continue control

      Unlike the ABP system alone, the CCP has the possibility to do the automayica calibration of the pumps and to have a continuous control of the quantity of liquid in the cycle. Thanks to a system of separate sclaes for each liquid, the quantity of liquid used is controlled in real time during the mixer cycle and thanks to the alarm thresholds the liquid in the mixer is under control so as not to compromise the quality of the preparation of the sand mixture.


      Self learning

      The self-learning software is able to save in a Data Base, every movement that the operator does with the mixer, for each model that is formed and thaen replicate it. Formules will be crated where the operator has the possibility to save the type of program (% sand binders) and model code to be formed. The mixer movement area will be delimited by safety barriers that will be active during the automatic mixer movement.


      Cleaning circuit

      Cleaning liquid group for mixing arm, consisting of a tank for cleaning liquid, capacity 50 liters and piston pump with pneumatic drive, pipes and connection fittings, liquid injection nozzle on the mixing tank with compressed air nebulizer. Operating button on the machine control panel.


      Cyclone

      Cyclone separator for dust discharge from the mixer mouth and from the first arm conveyor belt (if installed). The cyclone separator consist of a fan mounted in to a cylindrical and conic casing. The shape of teh separator body causes an internal air cyclone which, due tp centrifugal force, separates the particles with a higher specific weight based on the gravity principle. Sleeve filter for dust filtration.


      Mixer control

      -Hanging push-botton on mixer head

      -Push-botton on culumn, equipped with buttons for program selection, start/stop mixer, start/stop cycle and joystick for mixer motion.

      -Remote control with buttons for program selection, start/stop mixer, start/stop cycle and joystick for mixer motion. It will be also supplied a wiring panel with 15 m cable in case of malunction or breakage of the remote control.


Fast Loop moulding line

Fast Loop Moulding systems for flask or flaskless moulds bonded with self-setting sand, manual or automatic operation with different levels of automation. Horizontal or vertical stacking pouring and cooling lines. Up to 60 moulds/hour production rate.
  • Typical fast loop

    Fast Loop moulding and chemical hardening systems enable the best use to be made of the most modern binders, even those which harden very quickly. In Fast loop plants, the individual operations are carried out independently of one another. This means that the individual cycle time can be minimised, whilst conforming precisely

    to the time needed for the particular pattern in production. As the plant layout is very flexible, this means that every plant can be adapted to the particular requirements

    of the customer’s production flow. The modular concept which we have applied, also means that there is excellent project adaptability to the foundry space available.

    The degree of automation can be varied widely to match it to the operating requirements.

  • Fast loop area

    The moulding system has three main areas: the mould preparation area, the moulding area and the mould stripping area. These areas are connected by transfer equipment, each of which operates independently in transferring the pattern plates to the nearest free sector for the next operation. It is possible to process

    6 to 8 patterns with different dimensions at the same time. The system is completed by the auxiliary equipment for painting, for closing and by the moulding conveyors for the pouring and cooling lines, as well as by the shake-out area.

Shake-out and sand cooling

Shake-out grids and units for moulds or flasks. Sand cooling and lump breaking plants
  • Shake-out

    Constituited by: mai grid – special springs for support and vibration isolation– vibrator connected by shaft – material discharge.

    The main grid is made by strong electro-welded steel. It easily breaks down moulds for castings’ recovery; and also separates runners and risers for recycling. The upper surface of the grid may be flat, or spiked to assist in mould breakdown. It may also be sloped towards the casting recovery point to make casting removal easier.

    Bolted grids can be supplied on request, for customers wishing to be able to replace component parts.

  • Continuous shake-outs

    These are used when it is necessary to move the castings during shake-out. They enable castings to be discharged into carriers or their removal with remote controlled manipulators, with riser removal. They have the same characteristics as standard machines and are available in several sizes.

  • Vibrating grids

    These differ from shake-out machines in that they use vibratory motors instead of eccentrically loaded shafts. They are smaller machines and are more suited for “light” applications.

  • Sand cooling

    When the sand is very hot, a fluid bed sand cooler with a water cooled heat exchanger, is mounted under the shake-out machine. The heat exchanger water circulates to its own evaporative cooling tower. The cooled sand is conveyed pneumatically to the reclamation plant.

Sand Reclamation plants

Mechanical, thermal and dynamic sand reclamation plants suitable to No-Bake.
  • Mechanical sand reclamation

    This mechanical foundry sand reclamation plant uses the grinding action between the sand grains to remove/reduce the resin filmcovering them. These are simple

    operations, namely:

    A) cleaning the sand grains; B) dust removal; C) final screening; D) cooling.

    These four operations start at the shake-out and are completed in a vertical tower operating under suction through a sleeve filter. WSS sand reclamation plants can

    be used in any foundry for the reclamation of sands with any ofthe main chemical binders.

  • Gas fired sand reclamation

    Constituited of main elements: gas plant – fluid bed calcination – cooling – extraction, process control, it’s a system that guarantees: simple and extremely efficient, low operating costs, high quality reclaimed sand, low noxious emissions and process always under control.

  • Dynamic sand reclamation

    This system is particularly good for reclamation of the alkaline phenolic binders and for the furan, phenolic and polyurethane binders when the sand to metal ratio is unavoidably high.

Pneumatic transport systems

Pneumatic sand distribution and storage systems. Pneumatic transports are systems that transport new silica or reclaimed sand, or specials sands to the usage or processing points. They are composed of various assembled items according to the requirements and they use compressed air as transport which must be dry and oil-free.
  • Propulsors

    Propulsor for dense-phase pneumatic transport, from 125 l to 750 l capacity, delivery up to 40 tonnes/h. Completely automatic and manual operation to convey sand, bentonite, starch, cement and any type of dust from filters, with maximum temperatures up to 200° C. Operating with a reduced consumption of compressed air, with pressure from 1 to 4.5 kg/cm2. Much reduced maintenance. Tested according to PED. standard. First class components suitable for continuous operation in difficult environmental conditions.

  • Components and accessories

    The range for the realization of pneumatica transportation is completed by: caplet valve – line booster – Terminal box – electric panel – butterfly valve – slide gate valve – elbow sections – level probes – safety valves – felt sleeve filters - clapet valve – dome valve – silos.

Manipulator

Manipulators for flasks and mould, particulary suited for: painting operation – Closing and coupling operation – Maintenance and flasks preparation – positioning on the lines.
  • Chain manipulator for flasks

    This simple device is used to manipulate and to rotate flasks of different dimensions along the trunnion axis. It greatly assists the operator in all flask movements, since it gives fast and safe operation. The manipulator hangs on a lifting device, usually a crane or a bridge crane. Two powered chain support and drive unit move independently

    along the main support beam. They are driven back. It is therefore easy to regulate the opening of the manipulator and to fit it to the different flask dimensions. The pocketed chain wheels are driven together by a splined driveshaft along which they slide back an forth, creating a flask rotation.

    The electrical components necessary to control the motors are positioned on board the manipulator for installation compactness. The operator controls the manipulator operations through a remote push-button panel, similar to those commonly used for the bridge cranes. As an alternative a radio control is available. There are different

    manipulator models, according to the required capacity and to he dimensions of the flasks to be handled.

  • Hand manipulator

    It provides the clamping of moulds or flasks, according to the type of clamps fitted, for their lifting and rotation. The machine is used hanging on a lifting system. The clamp opening and closing are obtained by a hydraulic cylinder, whose clamping strength is infinitely adjustable while a reducer hydraulic motor unit provides the clamp rotation in both directions.

    All electric and hydraulic devices are assembled on board of the machine, requiring only a primary electric supply, and the controls are gathered in a single easy to use push button panel. An optional movement device of the hanging hook is available to compensate possible imbalances due to the mould shape. The particular shape of the clamps and the compensating system guarantee a safe clamping also in case of electric supply cut off.

Robot sistems for moulding and handling of flasks and moulds

  • Single robot station for moulding and handling of flasks and moulds

    Robotics cell for moulds and flasks with max weight of 350-400 kg, allows different stages of the production cycle to be carried out in extremely reduced spaces. The robot, set up with a suitable gripper, manipultaes falsks and moulds, positionig them in total autonomy in harrdening area, painting area, drying and mold assembly area. At the end, the robot managing the closing and the positioning on the casting line.

Automatic vertical wareahouses

Vertical wareahouses for storing flasks and other material (plates, cores, cooling flasks, falsks waiting for casting phase etc.)
  • Vertical wareahouse

    Tipcally composed of a trellis structure for the product post and a stacker for the operation of picking and depositing the loading units. The vertical wareahouse can be used either as a pure storage warehouse (plates, model, etc.) or as a cooling station or both at the same time.

Robotized deburring cells

Robotized automatic fettling cells for cast iron, stil casting, alliminum castings.
  • Robotized deburring cells.

    WSS deburring systems, with single or multiple robot, have hight flexibility and compactness. Depending on the processing requirements and/or the dimensions and the weight of the casting, the solutions are realized with the robot wrist tool and tool change stations, or solutions with workpiece handling and single fixed tool units. The cells can integrate various types of tools and processes including grinding (belt and disk), drilling, milling, rotary and alternate filing, punching, contouring etc. Loading and unloading operations can be managed with various solutions based on the customer's needs. Solutions with rotary table or conveyor belt and vision system are among the most common.

Management - Foundry 4.0

  • Plant Management software

    This program enables the overall productive process and individual machines, to be precisely controlled. An easily used man/machine interface, with keyboard and screen, enables the working of the whole plant to be reviewed, and process variables to be input/monitored. Individual machines can be performance checked directly, and their production parameters adjusted. This management system gives a high degree of automation, speeds the production processes and minimises faults.

    The parameters database which also holds all the historical production data, enables event analysis and data comparisons to be carried out, as an aid to production effectiveness.

    The main software caracteristics are: Dynamic synoptic display, the main process can herefore be examined in real-time; Diagnostics function enables machine states to be checked; Pattern tracking for a dynamic display of the patterns in production on the plant; Pattern Database holds all the data which identify each pattern together with the parameters for its production.

Compatible Spare Parts

Compatible Sare Parts for No Bake Foundry
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Electric Panels

  • Electrical Panels MT
  • Electrical Panels BT
  • MCC Motor Control Center
  • Quadri elettrici di distribuzione
  • DCS / ESD systems
  • Command and control Electrical Panels
  • ATEX panels for specific needs (Ex-d; Ex-p; Ex-e)
  • ATEX panels for intrinsic safety signals

Revamping

  • Electrical Panels
  • Control system
  • Replacement of obsolete components
  • Wiring on-board (primary, secondary and electrical)
  • Replacement of instruments

Technical assistance

  • Technical assistance Switzerland / abroad
  • Electrical and mechanical assembly
  • Supervision and commissioning
  • Tele-assistance