Automatic Pouring System

Why choose Automatic Pouring System?

In the fierce competition, everyone is pursuing higher efficiency, better quality and quicker rhythm. For foundry enterprise, how to pour faster with better accuracy and safety is an unavoidable topic. Traditional pouring, either by tundish or semi manipulator or manual scoop, some problem is inevitable: 1. a lot of human labor needed; 2. not accurate enough, molten waste oftenly; 3. pouring temperature is not ensured, causing more defecting rate; The demand for Automatic Pouring System grows higher and higher.

Rongke Automatic Pouring System: Smarter, Better Accuracy, More Reliable

● Bottom type un-heated pour machine

Scope of application

The pouring machine has removable module heavy duty ladle with good insulation effect, specially suitable for grey iron, ductile iron, vermicular graphite cast iron foundry or production need switch between different alloy. This pouring machine is convenient to tilt and maintenance, nozzle changing, feeding and pouring can be operating simultaneously. Self-developed vision align system along with high-end PLC control system and servo-driven stopper rod enable the system a sensitive, reliable and economic features.

Advantages

• Patented pouring ladle design
• Automatic liquid level compensation
• Low energy consumption and easy maintenance

Technical Advantage 1. Automatic level compensation, the pouring parameters is adjusted automatically based on the remained molten to adapt with the static pressure fluctuation. 2. Feeding and pouring can be operating simultaneously, the weighing system can show real-time the remaining molten. 3. Back-tilt frame, removable design, convenient to switch between different molten. 4. Patented tundish design, better insulated and less fading rate. 5. Bottom pouring, slag do not go into the molds. 6. No ground foundation needed, easy to monitor, operate and maintenance.simple installation. 7. Energy saving, low maintenance cost. 8. Rongke self-developed vision align system, avoiding over pouring or lack pouring.

Specification

● Bottom type heated pouring furnace

Scope of application

The heated pouring machine has series resonance lF power and high-efficiency induction coil, power factor always better than 0.95, featuring accuracy molten temperature control and flexibility like unheated type pouring machine. Co-ordinating with high-end control system and removable base, providing perfect solution for grey iron and ductile iron etc foundry.

Advantages

• Dynamic automatic correction
• Patented heating induction coil
• Using the latest medium frequency power system technology

Technical Advantage 1. Automatic level compensation, the pouring parameters is adjusted automatically based on the remaining moisture to adapt to the static pressure fluctuation. 2. Feeding and pouring can be operating simultaneously, the weighing system can show real-time the remaining molten. 3. Back tilting function, can drain the molten at one time, easy to change the molten. 4. Patented induction coil design, help to hold or raise the temperature accurately, keeping pouring temperature constant. 5. Overall heated evenly, prolong the nodulizing fading rate. 6. Slag is floating on surface under constant temperature, easy to remove. 7. Latest technology in the lF power, featuring high reliability and operation safety. 8. Rongke self-developed vision align system, avoiding over pouring or lack pouring.

Specification

● Automatic pressurized pouring heating furnace

Scope of application

Rongke pressurized pouring heating furnace has been equipped with high-end lF power with power factor always better than 0.95 and automatic pressuring system with nitrogen protection. especially suitable for foundry occasions which need accurate temperature control and exact pouring control like iron, copper base.

Advantages

• Automatic control
• Nitrogen protection and pressurization
• Precise air pressure control

Technical Advantage 1. Evenly temperature control, reducing overheating accidents and less lining building 2. Pouring can be adjusted automatically based on different mold parameters, controlled by vision align system. 3. Automatically controlled,servo-driven stopper rod &furnace base ensure faster and exact pouring. 4. With nitrogen gas protection and pressurization, effectively reducing the molten burning loss and prolonging the nodulizing fading. 5. All molten heated evenly, less slag on the slot and easy to remove. 6. Accurate pressure control, ensuring a constant level on the slot, no over pouring or lack pouring. 7. Back tilting function, can drain the molten. 8. Feeding while pouring, weighing system show the real time remaining molten.

Specification

Control System

The core of the Rongke pouring furnace control system is an industrial computer， processing all data from different sensors and controlling directly the pressure, servo, inoculant system, etc and communicating with other auxiliary equipment like molding line and so on. The software package in control system has everything the pouring system need and necessary expansion. Its function mainly including: Synchronized with mold line, automatically data storage and pouring menu mode. Remained molten weight display. Trouble pre-diagnosis in the maintenance program. Periodic cycling operation automatically or maintain running. Pre-setting of rated power. Main programm that connecting to the central network. Mode menu(button links to “vision pouring” or “pouring complete storage mode” page) Automatically inoculant(optional)(feeding dose depend on request) Cooling system. Vision pouring (optional) (button links to “pouring curve” and “vision system” page) Temperature display (button links to “history temperature” and “vision pouring” page) Vision system (optional) (button links to “vision pouring” page) Alert information (All alert information can be index in”history alert” page) The system is equipped with furnace leakage alarm system and detecting system. (button links to “parameters”, “language”, “system setting” and “code edit” page)

Rongke Automatic Pouring System advantages:

1. The control system can achieve automatic,semi-automatic and manual pouring; Operator can optimize the pouring process in different method and storage them conveniently in mode pattern, which is callable when same pouring
   pattern and editable before output to the pouring machine.
2. Storage of many menu is available, each menu can store multiple mode or pattern combination.
3. The control system has power control function, information of the induction coil like voltage, current, power, phase angle, resistance, reactance can be displayed, consumption calculation and visualization help to simplify the monitor on the induction coil.
4. The control system control the furnace inner pressure, pressure control is in linkage with the stopper rod to guarantee safety operation; Pressure and slot level is controlled automatically. All parameter settings including molten level, pressure limit, speed cureve etc can be set on the operator panel.
5. The operating interface is in simple design, operator need only to touch on the screen for different operation, its smart and flexible diagnosis and trouble shooting tools kit would help to find the failure source and solve them quickly.

Vision System

In the moving of mold line, the vision system would detect approaching of the pouring cup and position above the cup, identify the cup size and position with visual pixel; once the pouring start, the camera would check the cup inner level by reflection; By the high contrast between the molten and molds, the reflection won’t be affected by the pouring current, assuring a constant level, no lack pouring or over pouring; After finish, the data would be stored for further optimization.

Stopper Rod System

Pouring machine stopper rod system is equipped with a pneumatic stopper rod system and manual manipulate control system.

The system along with the servo driven rod make the move very delicate & reliable, easy to maintain. The operator can change the stopper speed and servo motor status by adjusting the inverter. The stopper has buffer design to reduce wearing; System can be reset to zero position from its present position, the stopper has rotate function so when slag begin to stick it can rotate to remove the slag.

Inoculant System

The control system is connecting with the inoculant system, by combining the inoculant system into the control system, operator can control the whole inoculant process, A variable feeding speed inoculant device can store the inoculant speed as part of the production formula. When the pouring change, the inoculant speed would change accordingly, no risk of wrong inoculant (if possible, lower the speed to save inoculant material). The feedback would be received by the control system, based on the setting, the alarm would be sound and interrupt the pouring if necessary.