한국신동공업(주)

Chemically-bonded sand process equipment

Suggestions that benefit from being reduced

Labor Labor saving

Manual work → Mechanization
FLASK TYPE - FLASKLESS : No FLASK return required

Material No waste sand

Sand fill support by RFID: Elimination of waste sand
Function of USMX Mixer: Elimination of waste sand*

Space Space saving

Flask type - Flaskless: No flask storage required
PITLESS devices:reducing space

Power Energy saving

FLASK TYPE - FLASKLESS: Saving lightweight return energy for mold

Keyword：Change to Flaskless System

OMEGA machines make it simple to build an automated, flaskless line.

FLASKLESS molds can be automatically ejected, inverted, coalesced, and returned.
Mold of various size can be handled.
Casting up to weight of 3 metric tons (Mold size=3.5 x 2.5m) can be produced.

Any size of mold within maximum size can be handled: Rollover, Pattern draw, Mold close, Transportation & Mold punch-out

Sand Waste Free Kneader

MixerOMEGA IRIS(= Intelligent Radio Identification System) control system

USMX

Mixer

When you want, where you want, just the amount you want		Automated control of sand, additives, and table vibrations with RFID technology	Benefits
Create a mold	Power outage, reverse control → New sand to all used sand * Depending on various conditions	Put a recipe on each of own mold The program recorded on the tag automatically sends the recipe to the kneader and vibration table Detailed data recording and reports: Material consumption, cost and production volume, production cost	Increase productivity Maintain quality Reduce material consumption by up to 20 Skillless manipulation
Creating a middle cast	Quantitative methods. → Discharge only the amount required for core manufacturing

LOI Measuring Unit LOI Measuring Unit Model LOIT

Low-cost production is possible by accurate measurement of LOI prior to mixing

Optimum sand reclamation

Normal sand reclamation and removal of fine
Optimum mold hardness

Accurate measurement of LOI prior to mixing
Low-cost production

Minimizing consumption of binder

Relationship between mold strength (kgf/cm²), LOI (%), and binder addition (%) (for alkaline phenolic resin process)
Binder Addition L.O.I	1.1%	1.2%	1.3%	1.4%	1.5%	1.6%	1.7%
1.0%			19			23	25
0.9%		17		23	24
0.8%		23	24	26			27

※ In general, adequate mold hardness for pouring molten metal is 20kgf/cm² and over.

The cost savings for a 0.2% (1.6%1,4%) reduction in binder addition is ₩3,250,000/month. (Monthly production of 100 tons, SM ratio=5:1)

Process flow for Low-cost Production

Keywords for low-cost production

#Low binder addition
# Minimal gas generation
# Low LOI of collected sand
# Energy-saved sand reclamation
# Improved reclamation yield = Reduced new sand addition + Reduced waste fine particle

Features of LOIT

1. Big reduction of measurement time

Conventional LOI measurement process

2. Easy operation

Measurement by LOIT

Measuring time reduction has been achieved by:: 1.Crucible design change (to flat shape) for better heat conductivity; 2.Concentrated roasting by furnace design change and utilization of rapid infrared heater; 3.Elimination of cooling time by built-in weighing mechanism

3. High measurement accuracy thanks to adoption of traditional “ignition loss method”

Accuracy of measured LOI value by LOIT is identical to that by conventional method using muffle furnace, because LOIT employs traditional “ignition loss method.”

Alkalic phenol process
±0.05%
Furan process
±0.1%

LOIT

“Capacitive” type LOI measuring equipment is not accurate because difference between Electric permittivity of silica sand and that of resin is so small. Measurement accuracy by capacitive type system ranges as under.

Alkalic phenol process
±0.3%
Furan process
±0.5%

Electric permittivity (ε)	Silica sand	3~5
	Phenol resin	3~12
	(Water)	80

4. Easy utilization of measured data

5. Specifications

Dimensions	580(W) x 630 (L) x 760 (1100 including screen) (H) (mm) LCD Panel: 8.4 inches
Weight	140 kg
Utility	AC100V 15A 50/60Hz
Furnace	Max. temperature 900°C / Initial setting 850°C
Dryer	Heater: Max. temperature 200°C, Set temp. 140°C, Sand temp. 100~140°C
Available process	Alkalic phenol process, Furan process, etc.
Measurement mode	Roasting and drying time are set by timer. Drying process separation (When it is ON, next sample can be dried during roasting.)
Data output	CSV format (via. SD card or USB memory stick)
Usage environment	To be installed on horizontal base or floor, Ambient temperature: 30°C and below, Clearance for 100mm needed around machine
Accessories	(3) Ashtrays for measuring ash content
Options	① Ethernet (LAN Port): Data can be transmitted to sand reclaimer (USR) to control reclamation degree. (Feed-back function) ② Installation base ③ Spare ashtrays for measuring ash content ④ Measuring spoon

KOREA SINTO CO., LTD

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