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Products to Shape Your Future l l l l l l l l l

Almost 50 Years Foundry Experience Wide Choice of Products Complete Turnkey Plants Plant Design and Consultancy Increased Productivity Improved Casting Quality Efficient Solutions To Customers Needs After Sales Service Project Management


Quality and Innovation FTL is a highly motivated and skilled organisation with almost 50 years experience supplying the UK and overseas foundry industry with innovative and high quality equipment. FTL Foundry Equipment has built up an impressive customer base including most of the UK’s leading foundries, who continue to invest in repeat orders from FTL, to help them maintain their competitive edge in the supply of quality castings. Prestige customers include, William Cook Group, Cosworth Technology, Weir Warman International, P.D. Castings, Federal Mogul, Harrison Castings, Grainger & Worrall, St Gobain, Alcan, Balfour Beatty, Bradken, Ardemir, Vanguard Foundry, Buyuk Eker and many others. FTL provides its customers with technically advanced solutions backed up by a wide range of high quality equipment. The product range includes mould handling systems for both green sand and No-Bake, green sand mixers, Moldmaster High Pressure Moulding Machines, moulding boxes, pneumatic and vacuum conveying systems, cupola melting and vibratory furnace chargers.

No Bake Mixing

Continuous Mixers, Compaction Tables and Process Control Systems

No Bake Moulding

Carousel, Fast Loop and Linear Moulding Plants, Rollovers and Manipulators

Sand Reclamation

Mechanical, Thermal and Chromite Sand Reclamation and Pneumatic Conveying Systems

Green Sand Mixing and Moulding

High Intensity Mixers, Green Sand Preparation Plants, Moldmaster and Rotary Knockout Drums

Other Equipment

Lost Foam Moulding, Cupolas, Furnace Chargers, Ladles and Ladle Heaters


No - Bake Mixing l l l l l l l l

Single Arm Continuous Mixers Articulated Arm Continuous Mixers Screw or Belt Primary Arm Mobile Mixers Range of Multiple Sand Gates Mixer Process Control Systems Compaction Tables Pattern Tagging Systems


Products To Reduce Your Costs FTL’s high efficiency mixers, single and articulated arm, are robust, reliable and easy to maintain. Electrical controls ensure maximum usage of mixed sand with multiple sand gates to cater for selection and blending of different sand types.

FTL No-Bake Standard Mixer Range Model

Type

Capacity (TPH)

CM3

Single Arm

1-3

CM5

Single Arm

3-6

CM10

Single Arm

6 - 12

CM20

Single Arm

12 - 25

CM30

Single Arm

25 - 35

CM40

Single Arm

35 - 45

CMA 10 (S)

Articulated Arm (Screw)

6 - 12

CMA 20 (S)

Articulated Arm (Screw)

12 - 25

CMA 30 (S)

Articulated Arm (Screw)

25 - 35

Articulated arms can be screw or belt type to give fast changeover of sands without cross contamination. Powered slewing can be fitted to both primary and secondary arms.

CMA 10 (B)

Articulated Arm (Belt)

6 - 12

CMA 20 (B)

Articulated Arm (Belt)

12 - 25

CMA 30 (B)

Articulated Arm (Belt)

25 - 35

Process Control Systems (PCS) have been designed using state of the art PLC and touch screen displays to precisely control the mixing process. Accurate control of binder and hardener pumps together with temperature monitoring enable the chemical feed rates to be controlled under all conditions, maintaining high quality moulds with fast consistent strip times, reduced chemical usage, less waste and low odour emissions. The control systems are fully integrated with FTL’s range of mixers and can also be fitted to existing mixers to improve their performance. Flow monitoring and control of binders and hardeners is also available as an option with FTL’s PCS3 Process Control Systems.

CMA 40 (B)

Articulated Arm (Belt)

35 - 45

CMA 60 (B)

Articulated Arm (Belt)

45 - 60

The mixing arms are designed for easy cleaning, twin opening side plates give complete access to the mixing shaft. Mixing shafts are easily removable, fitted with hard wearing blades, tungsten carbide tipped at the binder inlet section. Safety switches are fitted to the opening doors to prevent access before the shaft has stopped.

FTL Compaction Tables comprise a rigid steel framework supporting a set of gravity or powered rollers. Below the roller frame is mounted a live vibrating frame with lift bars which project through the rollers to raise the pattern bolster clear of the rollers during compaction. The live frame is fitted with two out of balance motors and is supported on air mounts for table lifting operation. Compaction table frequency can be varied to suit different box sizes and weights using inverter controls. Available with load capabilities up to 10,000kg.


No - Bake Moulding l

Carousel, Mould Loop and Shuttle l Moulding Plants l Rollovers l Mould Manipulators l Flood Coating and Tilt Stations l Coring and Closing Conveyors l Mould Pouring and Cooling Systems


Automated Casting Production One of FTL’s success stories lies in the field of no-bake moulding lines, designed to operate with a wide range of chemically bonded processes. Such layouts, based on automatic pattern re-circulation loops, transfer cars and powered mould accumulating tracks provide the foundry with flexibility to produce very accurate castings, with minimal labour at high rates of production. Custom-designed , whether for iron, steel or aluminium, FTL no-bake lines usually feature an automatic moulding loop with a pattern box filling station served by a continuous mixer, a vibratory sand compaction table, a combined pattern rollover and strip unit for stripping the cured half mould; tilt spray station and mould handling manipulators. Mould pouring and cooling tracks accommodate varying cooling times and metal specifications. In most cases, castiron pallets, running on raised tracks move closed moulds through pouring and cooling. Powered transfer cars and hydraulic pushers or powered rollers index the moulds and pallets along the tracks.

Control sequence is by plc panels or advanced automated computerised systems, capable of tracking the position of individual moulds in the circuit, their contents, metal requirements, cooling time, and other production parameters.


No - Bake Moulding l l l l l l l l

Increased Production Reduced Labour Costs Low Capital Costs Reduced Scrap and Fettling Reduced Sand and Resin Costs Accurate Moulds and High Quality Castings Flexible Production Automated Control Systems


Automated Casting Production Mould handling systems are tailored to suit each foundry utilising a combination of standardised products. Moulding carousels, fast loops and shuttle systems are selected to meet all production requirements with varying mould sizes, curing times and production rates, designed to suit the available space. FTL can offer a full range of ancillary items such as: • • • • • • • • • • •

Automated mould identification and tracking Rollover strip machines, fully or semi automated. Flood coating stations. Mould drying. Coring and closing conveyors. Pneumatic, hydraulic or electric Manipulators with rollover facility where required (Lift capacity 250kg - 9000kg) Mould pouring and cooling systems. Transfer cars. Hydraulic pushers. Mould lift and wipe off systems. Knockout and reclamation.

Rollover

Minimum (mm)

Maximum (mm)

Bolster Width

600

2250

Bolster Length

700

3200

Strip Depth

150

900

Carousel Model

No. of Stations

Bolster Width (mm)

Bolster Length (mm)

CU600/8

8

600

600

CU750/6

6

750

750

C900/6

6

900

900

CU1200/6

6

1200

1200

CU1200/6 (S)

6

1200

1700


Sand Reclamation l l l l l l

Shakeouts, High and Low Level Attrition Units, Elevators, Cooler/Classifiers, Pneumatic Conveyors Compact Knockout, Reclamation, Cooling and Conveying Systems Low Maintenance and Capital Costs Separates Sand and Castings, Reduces Sand Lumps to Grain Size, Elevates, Cools and Classifies No Pits Required for Combined Knockout and Reclamation Systems Robust, Reliable and High Quality Build


Mechanical Reclamation Systems FTL Shakeout and Reclamation units are available either as separate units or combined to suit the application. For smaller moulds and capacities (up to 2000kg load and 12TPH throughput) combined shakeout and attrition units offer low loading height and minimal foundation requirements. Vertical or inclined vibrating elevators further reduce the need for pits with the ability to feed directly into cooler/classifiers or pneumatic conveyors. Their compact design enables the system to be pre-assembled then quickly installed and commissioned without extensive foundations. A full range of attrition sizes are available for up to 20TPH complete with fluid bed classifiers, coolers and pneumatic conveying systems for both hot and cold sand applications. Larger moulds may require a heavier duty shakeout, for such applications FTL can offer heavy duty non-discharging vibratory shakeout with unbalanced motors or shaft drives, with capacities in excess of 25,000kg. These units are frequently mounted directly above, or used in combination with, a high level discharge vibratory attrition unit, again to minimise pit depths. Attrition units are fitted with replaceable screens and wear plates and reduce sand lumps to grain size. Oversize material is discharged separately and clean out doors are provided for tramp metal removal.

Model

FTL Attrition Type

Capacity (TPH)

Deck Size (MM)

CEA3

Compact economy unit

1-3

1000 x 900

CA3

Low level discharge

2-3

1030 x 980

CA6

Low level discharge

4-6

1500 x 1490

CA9

Low level discharge

7 - 10

2030 x 1980

CA12

Low level discharge

11 - 12

2030 x 1980

CA5H

High level discharge

3-5

1500 x 800

CA10H

High level discharge

6 - 10

1800 x 1100

CA15H

High level discharge

12 - 15

1688 x 1350

CA20H

High level discharge

15 - 20

1600 x 1500


Products to Reduce Your Costs

Sand Reclamation l

Thermal Reclamation Units l Chromite Separation and Recovery Plant l Reduction in New and Chromite Sand Purchase l Reduced Dumping Costs


Foundry Sand and it’s Recovery The foundry industry is under extreme pressure both financially and environmentally in the buying and disposal of sand, which is an essential element in casting production. Disposal by dumping is becoming increasingly expensive and even more difficult if the sand has Chromite contamination. It is important that foundry’s optimise sand systems to help control their sand efficiently and minimise costs. FTL is able to offer in addition to our range of primary mechanical reclamation, two systems for further treatment of sand to greatly reduce dumping costs: 1. Thermal Reclamation Unit 2. Chromite Separation and Recovery Plant The FTL – Thermal Sand Reclamation unit comprises a gas fired furnace followed by a two stage cooler, all operating on the fluidised bed principle. Capacities range from 250kg/hr up to 4000kg/hr. Mechanically reclaimed sand from the mechanical attrition system is fed to a small receiving hopper. It is then fed into the thermal unit’s furnace body via a screw feeder passing through a vibrating screen to ensure that oversize material or sleeve materials are removed. This screen also acts as a tramp metal removal system, in the case of non-ferrous applications. Provision can be made for additives to be introduced to the process if Alkaline Phenolic coated sands are to be reclaimed.

The FTL Chromite separation and recovery plant is a three stage process: 1. Removal of ferrous materials 2. Separation of Chromite 3. Scrubbing and classifying of Chromite The use of chromite for facing sand together with reclaimed silica backing sand will lead to a build-up in the levels of chromite in the reclaimed backing sand. These levels can frequently build up to 15-20% causing problems with the reclamation process, increased resin and catalyst/ hardener usage and increased fettling costs due to poor casting surface finish. In addition, the high cost of new chromite purchases and the ever increasing dumping costs further highlights the need to recover the chromite from the reclaimed sand for reuse, reducing the costs. The separation of chromite from contaminated reclaimed sand can be achieved by the use of a rare earth magnetic drum, reducing chromite contamination levels to below 2-3% and producing a reclaimed chromite with a purity in excess of 90%.


Green Sand Moulding l l l l l l l l l l

FTL’s Moldmaster High Pressure Green Sand Moulding Machine High Production (60-150 Moulds/hr) High Pressure Moulding and Box Handling Reduced Manning Pattern Change Within Cycle Programmable Sprue Cutting Jolt Facility for Deep Cods and Pockets Programmable Controls with Operator Interface Hard Accurate Moulds Low Noise and No Vibration


Automated High Pressure Green Sand Moulding 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

FTL Moldmaster High Pressure Jolt Squeeze, 3 Station Moulding Machine Programmable Sand Feed Louvres Sand Weight Metering Hoppers Pattern Change Carousel Drag Line Cope Line Mould Rollovers Drag Placer Automatic Sprue Cutter Mould Transfer Cars Mould Pallets Sterling Flasks (1200 x 820 x 356/356)

13. Cope Closer 14. Weight Transfer 15. 1000kg Lip Axis Ladles 16. Lift Unit To Punchout 17. Shakeout 18. Casting Twin-Mass Feeder 19. Casting Manipulator 20. Box Splitter 21. Pallet Brush 22. Machine Sand Feed Hoppers 23. Aerator 24. Control Room

FTL’s Moldmaster high pressure green sand moulding machine continues to lead the field today as it has over the past 20-30 years. The Moldmaster produces moulds of high uniform density and rigidity resulting in sound, accurate castings to meet today’s demanding market. The latest machines include state of the art hydraulics, weighing and PLC controls to maintain high productivity and reliability. FTL has taken the well-established Moldmaster high pressure, greensand, moulding machine and updated it to meet the exacting requirements of today’s high production iron founders. The four-poster design employs multiple squeeze feet, each with its own independent hydraulic cylinder. This arrangement allows the sand to be moved around as it is compacted, to suit the pattern

contours. Vertical and horizontal faces are rammed hard with only a few points variation over the whole mould. Inner and outer feet are separately controlled, hydraulically, for higher pressure along the box wall. The Moldmaster is available in a number of variants, including two and three station layouts, duplex Moldmasters to suit smaller box sizes, rotary indexing machines and in-line Moldmasters for high output rates on a single-pass line. A jolt facility can be incorporated to cater for deep pattern cavities which can be programmed on or off as required. The rigidity of Moldmaster moulds allows large, deep cods to be stripped without support or rolling over. Previously cored parts can be moulded, reducing costs and manning, and casting weights can be reduced maintaining tight mould tolerances and rigidity.


Green Sand Moulding l l l l l l l l l l l

High Intensity Green Sand Mixers Complete Integrated Green Sand Plants Rotary Knockout and Cleaning Drums Rapid Homogeneous Mixing Low Operating and Maintenance Costs Automatic Moisture Control and Batch Weighing High Quality Sand Automated Sand Plants Additives Bulk Storage and Pneumatic Conveying Programmable Control Systems In House PLC Panels


Preparation and Control of Green Sand Systems Central to FTL’s activities is the mixing and control of high quality green sand essential for the operation of today’s moulding lines. FTL supplies high intensity mixers and complete integrated sand plants. FTL has also achieved considerable world-wide success with its automatic moisture control system. However advanced or complex, today’s green sand moulding machines are still reliant on the efficiency of the foundry’s sand plant. High quality moulds can only be produced from high quality sand. FTL’s automatic moisture controller measures the moisture content and temperature of the sand as it feeds into the mixer batch hopper prior to mixing. It then calculates the exact amount of water to be added to the sand batch discharged into the mixer to bring the moisture content to the required level. Variations in temperature both of return sand and ambient air can be measured and compensated within the software. The system can include integral batch weighing of sand and additives. High Intensity Mixers FTL is the UK’s leading manufacturer of high intensity green sand mixers, typified by the 2000 Series. These PLC controlled mixers employ a combination of rotating pan, low speed stirrer and high speed agitator to thoroughly mix the sand, water, clay and other additions. The pan and walls are fitted with removable bonded rubber wear resistant liners. Other features include a central hydraulically operated bottom-discharge door, with rapid discharge plough to empty the mixer, minimising cycle times. Automatic centralised lubrication ensures even distribution of lubricant to all parts of the mixer. A wide range of sizes are available with the FTL 2000 Series, from 10 to 100 tph. Automatic Moisture Control

FTL’s expertise in sand preparation has also brought many orders for complete integrated sand plants. Such systems can incorporate bulk storage and feeding equipment, pneumatic conveying systems, batch weighing, and sand cooling facilities, in addition to the mixers and moisture controller. Rotary Knockout and Cleaning Drums DIDION Rotary Media Drums take castings and sprues directly from the moulding line through a highly efficient separation and scrubbing process by means of a gentle tumbling action. A specially formulated, recirculated media removes even the most stubborn cling and core sand. Such is the efficiency of the concentrated process that savings on shot blasting of up to 60% have been confirmed. The Drum’s simple, smooth, low power, rotary drive system eliminates vibration, excessive foundation loads and reduces maintenance.


Other Equipment l l l l l

Lost Foam Moulding Molten Metal Treatment and Handling Moulding Boxes Casting, Cleaning Cooling and Inspection Materials and Mechanical Handling Systems

FTL meets today’s criteria of understanding the market and delivering solutions that are reliable, on time, more productive and cost-effective.


The Competitive Edge FTL specialises in both stand alone and turnkey equipment being able to offer consultancy backed up by practical experience and design expertise. FTL’s extensive technical and process knowledge helps to ensure the development of cost effective solutions that can be brought up to full production with the minimum of disruption. This enables customers to quickly achieve improved casting quality, productivity and payback. FTL has the expertise and capability to help customers develop and expand production output. A proven track record for reliability, quality and above all full commitment to providing the right solution for its customers, has helped maintain FTL’s position as one of the UK’s top suppliers. FTL provides a wide range of high quality reliable equipment, not only in No Bake and Green Sand Moulding, but also in Lost Foam Moulding with a range of vibratory compaction filling stations and automated mould handling equipment. FTL has expanded it’s well proven, robust and reliable mould handling into more specialised fields such as automated mould assembly, storage and cooling. FTL also can provide a number of products for molten

metal treatment and handling, including: • Cold blast and hot blast cupolas • Emission control • Melting and electric furnace vibratory chargers • Ladles and treatment vessels • Lip axis pouring ladles • Monorail systems • Metal transfer The latest generation of FTL/Wrib long campaign cupolas can provide impressive quantities of hot metal to close specifications, hour after hour. Particulate emissions are contained to below 20mg per cu.m. FTL also has a wide range of vibratory equipment developed over many years of practical experience in the foundry industry including, vibratory sand conveyors and casting cooling conveyors. FTL are specialist in materials and mechanical handling systems and can offer as part of our product range: • Storage silos • Blowing systems • Weighing and blending • Vacuum cleaning and handling FTL’s reputation has been extended to the growing export markets with significant overseas contracts in Russia, Poland, Turkey, Scandinavia, Spain, France, South Africa, Japan, Australia, Malaysia and the Middle East.


FTL Foundry Equipment Ltd. 6-11 Riley Street, Willenhall, West Midlands WV13 1RH England. Telephone: (+44) (0)1902 630222 Fax: (+44) (0)1902 636593 Email: sales@ftl-foundry.co.uk Website: www.ftl-foundry.co.uk

FTL Foundry Equipment Ltd (UK)  

Каталог самого популярного в России оборудования для ХТС-процессов от ведущего поставщика - от компании FTL. Дополнительная информация и зак...

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