48 LOWER ENERGY CONSUMPTION In this new equipment, roller screw technology is used instead of hydraulic pumps to allow safer, faster, less energy dependent movement of the upper platen. Also, flash detection on the parting line, leak prevention, adaptive (intelligent) mold closing for applying appropriate clamp force to reduce the mechanical stress in the mold and prolong its life. Current low-pressure casting machines use large hydraulic pumps using high amounts of electrical power–12 kW or more. Additionally, their duty cycle is longer—using double the electrical consumption. The substantial energy savings with the elimination of hydraulic pumps is truly amazing—as the average electrical consumption (without the furnace) is about 5 kWh with this new pressure-assisted casting system. To reduce furnace energy consumption, horizontal immersion heaters are used to minimize the generation of oxides. This reduces furnace energy consumption dramatically. The large, bonded particle filter separates the charge area from the pump chamber. The bonded particle filters prevent the resuspension of oxides by reducing the metal velocity, helping to make higher quality castings. REDUCE WASTE Eliminating hydraulic cylinders means no costly oil / hydraulic fluid waste disposal. It also means no compressed air is needed, further reducing casting costs. HIGHER QUALITY Incorporating a precision pump ensures flow rate and pressure profile to properly fill the mold. Eliminating compressed air to move the metal into the mold increases metal quality. The precision casting pump uses a float attached to the ceramic foam filter on the bottom of the pump to provide a secondary filtration of the metal. The filter separates when it’s lifted from the bath. The ability of the pump system to hold metal at a consistent level very close to the mold reduces oxide buildup inside the riser tube. The overall temperature of the pump is less, which impacts the amount of shrink in the casting— and a significant advantage over low pressure casting systems in regard to producing higher quality castings. HIGHER ACCURACY Replacement of the hydraulic actuators with electrical actuators in all units provides real time measuring of the stroke and force with higher accuracy 0.05mm and 1kN increments. Being competitive on a global scale is only getting harder. It’s time to look at your equipment to reduce high energy and maintenance costs while reducing disposal costs. Global automotive, aerospace, electronics, and consumer companies are routinely asking foundries to detail their sustainability plans. This type of equipment easily meets all of the benchmarks for a strong sustainability initiative. To begin the process, conduct your own energy audits to know how impactful these new equipment innovations will be to both the bottom line and global competitiveness. Contact: JOHN HALL jhall@cmhmfg.com
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