RTC 106

Optimisation through moisture measurement and compressibility measurement.

A moisture measurement on the belt feeder records the actual moisture in the sand and makes an exact determination of the pre-water possible. The formula value of the target moisture is controlled against the compressibility margin to the target value. If the compressibility is too low, the moisture target value is increased and, vice versa, if the compressibility too high, the moisture target value in the formula is decreased. Of the two measurement processes, this combination process improves the precision while not compromising the flow rate.

tl_files/fotograf/grafik/RTC_106.PNG

Task:

Bentonite-bonded moulding material is to be processed for the moulding facilities with reproducible, consistent values for the compressibility and mould stability.

________________________________________________________________________________________________________

Approach:

Samples are taken from the running mixing process and automatically used to determine compressibility and mould stability. These measured values will then be the parameters for water addition and bentonite dosing.

Solution:

The Rotocontrol RTC 106 gathers a sample quantity from the running mixing process. With the automatic measurement of the compressibility, the mould stability and the temperature, the currently needed amount of water is determined and subsequently added. For the bentonite requirements, a formula adjustment takes place. By means of the temperature measurement, the expected evaporation is determined and compensated by adding of water. Furthermore, all relevant data are saved and displayed on-line. Due to long-term storage, they will be available for future analysis.

tl_files/fotograf/grafik/RTC_106_1.PNG

Sämtliche Daten stehen durch die Langzeitspeicherungfür weitergehende Auswertungenzur Verfügung.

Advantages:

• improved moulding sand quality and therefore less scrap due to defective moulds
• higher profitability of the mould machine due to omission of holding times caused by bad moulding sand
• decrease of rendering input
• less scrap caused by moulding sand problems
• staff savings for the processing of moulding sand
• consistent process tracing through recording of all measured values
1. Sampling form the mixer
2. Compressibility
3. Mould stability

Simple installation

tl_files/fotograf/grafik/RTC_ruecks_1.PNG

On a simple frame, position the ROTOCONTROL RTC 106 directly at the speed mullor (Webac). After the measurement, the sand samples will be dropped onto the discharge belt.

tl_files/fotograf/grafik/RTC_ruecks_2.PNG

View from above onto the sand extraction from the mixer. The gate rotor is mounted to the mixer while the RTC sits next to the mixer and will be moved aside for maintenance purposes.

A proven improvement

tl_files/fotograf/grafik/RTC_ruecks_3.PNG

irregular compressibility

tl_files/fotograf/grafik/RTC_ruecks_4.PNG

regular compressibility

Illustration of recorded compressibility values from 2 production days, which show a definite equalisation since the operation of the RTC 106. During the irregular operation, only measured values were recorded.

tl_files/fotograf/grafik/RTC_ruecks_5.PNG

Each batch is recorded along with a final measurement during the opening of the mixer. Our analysis programme DView_Analyse was used to illustrate the margin between target and actual value of over 200 consecutive batches. The deviations are minimal.