Ensuring effective moulding sand preparation
- capacity range 15 to 200 t/h
- integrated conditioning of moulding sand
- uniform, optimum moulding sand quality – in various production modes
Technology
An intelligent preparation solution
A powerful and profitable batch-type sand mixer
- almost simultaneous filling of the sand mixer with return sand and a controlled water addition
- rapid blending by a high-speed rotor and immediate start of the effective mixing phase
- specific feeding of additives
Three bottom-wall ploughs rotating in anti-clockwise direction are designed to turn over and blend the moulding sand mixture and to move it back to the upper rotor section. Passing of the ploughs underneath the lower section of the rotor provides a thorough blending and compression (kneading) in this highly mixing-intensive area.
Simultaneously the upper sand layers are directed to and aerated by the upper rotor section.
The high shear and frictional forces of the rotor essentially contribute to a rapid but gentle blending and dispersion of the binders.
Continuous turning over of the rotating main sand stream by the bottom-wall ploughs working in anti-clockwise direction in combination with the rotor turning in clockwise direction provide a parallel kneading and aeration action.
An optimum moulding sand quality is the result. At the end of the mixing cycle the moulding sand is discharged from the sand mixer in an aerated and flowable condition.
KW rotary mixers are robust and proven sand preparation units fulfilling the highest requirements of preparation technique and belonging to the best aggregates of this type.
Construction
KW rotary mixers are particularly powerful, service-friendly and offer a high operational reliability. All areas susceptible to wear are provided with long-life, abrasion resistant and easily replaceable components.
Wall and bottom liners are available in a variety of qualities with guarantees for several years
Three robust bottom-wall ploughs of a special shape ensure a controlled circulation of the moulding sand.
High-speed rotors with strong shear and frictional forces contribute to a rapid dispersion of the added binders and coating of the sand grains.
Control
User-friendly process control and visualisation system
The basic version of the KW process control and visualisation system, designed on the basis of the latest control technology, has the following required functions:
- message and diagnostic system for process monitoring
- recipe management
- control features for automatic and manual operation
- setting parameters and batch and shift protocols for raw material consumption
The KW process control and visualisation system is of modular design offering a variety of supplementary functional modules for a stepwise upgradation.
We will always be at your disposal for technical advice about the available optional modules.
Integrated control of the moulding sand quality
Different foundry conditions require the use of different systems to control the moulding sand moisture and the moulding sand quality. Künkel-Wagner offers integrated real-time control systems as well as preventive control systems.
Moisture, compactability and moulding sand strength are recorded online, stored in a database and adjusted to the pre-set value.
Analysis
With a conventional sand preparation technology a relatively slow distribution and absorption of the water takes place. The moisture content is constantly increasing until the end of the mixing period.This prevents a rapid dispersion of the bentonite.
In the KW rotary mixer the highly efficient mixing phase begins immediately upon start of the mixing process. The moulding sand moisture increases considerably at the beginning of themixing process which is crucial for the dispersion of the bentonite and coating ofthe sand grains with a uniform film of bentonite.
