The system consists of a moulding line for automatic sprue drilling and core setting, rollover devices, closer with clamping devices, transfer cars and a cleaning station in addition to cooling lines, a punch-out station and an automatic flask separator.
The separating unit
The DISA FLEX moulding line starts with a separating unit setting the cope and drag flask on the moulding line. The emptied flask pair along with pattern plate will be transferred to Mould conveyor and lifted up to separate it from pallet. meanwhile gripper unit moves up/downwards to separate the cope & drag flask and transfer to the moulding machine.
Before the flasks move into the moulding machine special units clean the flask inside, the flask top surface, pin, bushes and checks the flask top surface for melt pearls burnt to the top surface. This feature ensures the smooth operation of the line and helps to improve mould quality. After the moulding machine, the excess sand on the mould back side is removed by a heavy duty sand cutter.
The rollover devices are specially designed to avoid sand spill on the mould. The motor drive is on the top of the station for easy service access.
DISA offers both a low cost pouring cup drilling station, where the position is set manually by the operator or an automatic drilling station where the pouring cup position is set automatically by data from the control system. For high production lines DISA offers fully automated vent hole drilling stations and core setting stations.
The flask closer is a very important unit. The cope flask is set on the drag with high precision, due to heavy guide rods and active position units of both cope and drag flasks. This ensures that the mould halves go together without distortion of sand and cores.
The finished moulds are handled by transfer stations with reliable frequency inverter drives which ensure good motion control and a long service life.
The cooling lines are equipped with robust hydraulic push and breaking cylinders for good control of acceleration and de-acceleration to ensure the safe handling of moulds.
A very robust mould punch out completes the system. The mould is punched out from the lower side, so the mould is pushed up. This gives a safe handling of the castings on their way to the shake-out. By lifting up the moulds the shake-out can be positioned on floor level for easy operator access to the castings.