Fully automatic clay sand production line

A significant, fully automatic clay sand production line was recently unveiled, revolutionizing the foundry industry. Developed meticulously by a team of industry experts, the line integrates advanced technology and innovative processes, and has garnered widespread attention since its launch.

This line integrates the entire sand preparation, molding, pouring, shakeout, and sand regeneration process into a single, automated process. The molding process utilizes cutting-edge static pressure molding technology. This technology operates by opening a static pressure valve, allowing compressed air to be evenly distributed within the air frame through a guide tube. This air permeation pre-compacts the molding sand through gaps in multiple contacts, followed by high-pressure compaction. This process is essentially a "pre-compacting" molding process. Because the pre-compacting process is quieter, it's called "static pressure molding." The compaction process consists of four stages: First, the sand hopper fills the flask with sand. The hopper then moves to the head of the sand-feeding conveyor to load sand. Simultaneously, a multi-contact pressure head, hinged to the sand hopper, moves above the flask. Next, air pre-compaction is performed. The hydraulic cylinder rises, tightly fitting the mold plate, flask, and auxiliary frame with the multi-contact pressure head to form a sealed system. The impact valve opens, and the shock wave generated by compressed air pushes the molding sand toward the mold plate for pre-compaction. The compressed air used to compact the sand is discharged through the vent plug on the mold plate and the mold frame. The third stage is compaction, where the multi-contact pressure head compacts the sand from the sand surface. Finally, mold removal occurs. The hydraulic cylinder descends to remove the mold, simultaneously moving the multi-contact pressure head out of the compaction position and moving the sand hopper above the flask and auxiliary frame, ready for the next molding process. This technology enables static pressure molding to achieve a mold removal rate of 97%, significantly improving mold yields.

The fully automatic clay sand production line has achieved remarkable results in terms of production efficiency. For example, after introducing this production line, one company achieved real-time data connectivity across numerous casting equipment, including the online batching and weighing system, automatic transfer system, and casting machine. The intelligent detection system can accurately identify errors down to the millimeter level, increasing order response speed by 30%. During the molten iron pouring process, operator labor intensity was reduced by 99%, and efficiency increased 20-fold.

This production line has a wide range of applications. The automatic static pressure molding line is suitable for clay sand molding and can produce large quantities of medium-to-large castings, such as automotive parts, wheels, pipes, manhole covers, textile machinery parts, and machine tool components. According to relevant data, castings produced using the static pressure line offer high precision, no sand sticking or expansion, and minimal seams. This significantly reduces cleanup and machining allowances. Furthermore, due to its excellent back-compacting strength, it can reduce sand consumption by 10% compared to air-blast molding, while also increasing mold cavity height utilization by 10%-15%.

Market feedback indicates that the fully automatic clay sand production line is highly sought after. Numerous foundries have expressed strong interest in it and have inquired about potential partnerships. Industry experts believe that the advent of this production line will effectively promote the foundry industry's accelerated transformation towards intelligence and greenness, and is very likely to reshape the industry landscape and lead the foundry industry into a new stage of development.