Celecta-Mold is a complete, automatic, no-bake sand, molding, handling and pouring system, capable of producing 100 molds/hour. This system can be designed to utilize a variety of mold sizes.
This system can accept up to six different molds at one time and offers automatic mold handling and closing. With EMI's expertise in custom adaptations, the length of the conveyor can be adapted to accommodate several work stations, including manual or automatic core settings. The heater, pattern change stations and continuous mixer help to keep productivity at its highest by maintaining required temperatures and limiting stopping or slowing time by combining sand binders uniformly for high quality results.
Celecta-Mold Drawing (jpg)
EMI No-Bake Loop System
EMI has designed "no-bake" production cells with modular construction to produce "no-bake" cores or molds. These cells may be fully automated with programmable logic control to automatically utilize system parameters such as box identification, facing sand requirements, sand fill, iron oxide addition, compaction time, intensity, cavity configuration, eject requirements, number of cycles run, and binder levels. These variables can be tracked for each box and the box order may be random during automatic system operation. Layouts can be designed in single- or dual-loop arrangements.
Modular equipment that may be included:
1. Compaction Table with Power Conveyor
2. Continuous Mixer
3. Binder Heater
4. Sand Heaters for both Facing and Backing Sand
5. Sand Storage Hoppers
6. Roll-Over/Draw Station (with tilt)
7. Bottom Board Destacker and Set Station
8. Necessary Transfer Stations
9. Power Conveyors and Idle Conveyors
9a. Box Change-Out System
10. Electrical Control System
11. Total System Engineering
A typical cycle begins at the fill and compaction station. A pallet identification system is used to identify each box at this station. Identification prior to the sand fill procedure is provided to ensure that the box receives the correct "recipe" of facing sand, backing sand, and binder. The operator will fill each cavity in the box with a measured amount of sand, based upon the set parameters in the PLC. This is also true for the addition of the binders, which eliminates wasteful mistakes by the operator. The temperature of the sand will be monitored to automatically adjust the quantity of catalyst that is introduced into the box. The mixer may be floor mounted with a 270° swivel for ease of distribution into the box.
Independent hoppers hold the facing and backing sands (if both are required) on a mezzanine above the production cell. They will accept sand from a pneumatic sand transporter and will hold a fixed amount of sand for a required production time. Both sands may be routed through sand heaters. They will be equipped with manual bypasses for warm summer months. Manual slide gates are also included for sand isolation at key points. Optional iron oxide hopper and power feeder may also be included.
During fill, a sound will alert the operator at the completion of the facing sand fill. If multiple cavity boxes are utilized, the sound will alert the operator to shift the facing sand feed to another cavity to assist in the uniform filling of the box. Programmed time delays between Sand Start, Mixer Motor Start, Resin Feed Start, and Catalyst Feed Start will be provided for both facing and backing sands. Also during the fill operation, the compaction table may be automatically actuated at predetermined times.
After fill, compaction, and manual strike-off, the box is moved to the bottom board destacking station. This unit will index the customer supplied bottom boards onto the top of the awaiting box. The box is then moved to the rollover/draw station.
The rollover/draw station accepts the box and bottom board package and rolls it over. The box is then stripped away while vibrators assist in the smooth draw. If ejection is required, the eject plates will be actuated at this time. Photo-eyes may be incorporated at this station to ensure the box has been stripped. The cores or molds are then moved out of this station, riding atop the bottom board. The station is then rolled back to start position and accepts a new box as the empty box exits the station.
A return conveyor section may be included for the operator to clean and replace any loose-piece tooling. The operator may also place chills at this location. The cores or molds and bottom boards are passed to the Customer's take away conveyor and the boxes are transferred back to the fill/compaction station to begin the cycle again.
EMI No-Bake Loop System Drawing (jpg)