Introduction of

PRINSID POURING TRUCK

Ottobre 2016

PRINSID

The company was born in 1981 thanks to the expertise its founder gained in one of the most important Italian foundries.

The present of Prinsid

PRINSID POURING TRUCK

Prinsid started to produce foundry ladles

Treatment transport ladle Treatment fixed ladle

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PRINSID

Prinsid goes on to produce ladles introducing new technology design system (cad – fem analisys)

Iron ladle New generation of foundry big ladles

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PRINSID POURING TRUCK

In construction

PPT500

In installation

PPT800

The truck consists of a frame equipped with 4 wheels, positioned on two rails laying along the forming line. The truck has a gear rack travellingmechanism for moving along the rails coupled with a tempered gear rack.

On board there are the drives, the motors, the electromechanical systems, the computer systems and, of course, the ladle for casting. Themachine can have the supervisor cabin OR the supervisor can work not on the truck but in another position with good visibility towards the pouringline.

A weighing load cell measure the weigh of the ladle and the amount of poured metal (and its speed in term of kg/sec). The ladle is lifted andautomatically moved to compensate the movement of the spout along the arc described by the rotation. The position of the spout will be correctedautomatically thanks to an appropriate software installed in the PC/PLC onboard.

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PRINSID POURING TRUCKMOVEMENTS

The machine has 4 axis of movement:

- X AXISthe rails

- Y AXISthe right/left movement of the ladle

- Z AXISthe up/down movement of the ladle

- W axisthe rotate/rotate back of the ladle

All the movement are performed by servo motors and reducers supplied by SEW EURODRIVE

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PRINSID POURING TRUCK - PROCESS

PROCESS EXAMPLE STANDARD INSTALLATION - LAYOUT

-The machine takes a new full ladle positioned on a fixed pointat the end of the rails.

-The machine has stored in his industrial PC on board thedata and the queue of the moulds to be casted.

-The machine positions the pouring nozzle correctly.The machine begins to cast, at desired speed, the desiredamount of molten metal.

-The machine finishes pouring in the mould n.1. If there is anew mould ready in the forming machine the truck standswaiting for mould line movement. If there is no a new mouldready in the moulding machine the truck moves and reachedthe next empty mould.

-The casting process goes on until the molten metal left in theladle in less than required for pouring the next mould.EXAMPLE: there are 8 kg left in the ladle but we would need20 kg to pour in next mould.

-The truck goes to a point where there is a sort of "waste box"to put there the extra metal present in the ladle. Then the ladleis

empty.

Standard installation – beside moulding line – 90 mould / hour

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PRINSID POURING TRUCK – layout

PPT500SC

- installed on disa line- remote control room

- roller cars for fast exchange

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PRINSID POURING TRUCK – layout

PPT800

- installed on disa line- ladles exchange in fixed position

- refilling with transport ladle

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PRINSID POURING TRUCK - MODELS

4 STRUCTURE AVAILABLE UP TO 1500 KG

PPT500 from 250 kg to 500 kg

PPT800 from 500 kg to 800 kg

PPT500SC from 250 kg to 800 kg

PPT800SC from 800 kg to 1500 kg

With operator cabin Without operator cabin

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PRINSID POURING TRUCK – STANDARD OPTIONALSTemperature control

The machine can be equipped with a temperature controldevice. The device controls the molten metal temperature andis able to stop the pouring process if the temperature of themolten metal is below XXX degreees. If in the ladle there ismolten metal that is colder than needed, the metal can bepoured in a waste box.

Inoculant system

The machine can be equipped with an inoculation system for metal refining. Theinoculation system is managed completely by the PC and PLC in term of quantity ofinoculation material AND timing.

Ladle pre-heating

The machine can be coupled with a ladle pre-heating system. Thissystem can be positioned on a point along the rails. Whenpreheating is necessary the machine with the ladle goes on aprecise point along the rails. The preheating system advacestowards the ladle and the burner begins to warm the ladle.

And others

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PRINSID POURING TRUCK - HMI

CAMMAND PANEL

Manual command for movements:

G - Joystick X axisTo go forward and back with the machine along the rails. Toadjust the speed, you can turn the trimmer identified by theletter I.

H - Joystick Y and Z axisThe joystick has 4-position: left / right (Y axis) and up / down(Z axis). To adjust the speed, you can turn the trimmeridentified by the letter I.

I – Potentiometer The rotation of the potentiometer on the notches marked 1 to10 changes the speed of the machine in manual mode. Thepositioning of the potentiometer at the value 0 freezes, infact, the movements of the machine in the manual.

L - Wheel W axisThe wheel drives the overturning moment of the ladle (axisW). To adjust the speed, you can turn the trimmer identifiedby the letter I.

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PRINSID POURING TRUCK - HMI

TOUCH SCREEN PANEL

The ladle's movements:

A - Reference axis

B - Quota to which the machine is located for that axis

D, E - Writing a quota in the field E and pressing the D button and the machine moves the axis until it reaches the quota

F - Joystick indicators

G -Parameter speed

The compensation of the ladle's movements:In the area of the touch screen panel dedicated W axis of rotation of theladle, there is the CASTING button shown the image below.

In manual, the green light of the CASTING button, enables the offsetting ofthe ladle rotation. In particular, the compensation of the ladle connects therotation of the same with lifting movement (Z axis) and translation (Y-axis).This logical connection makes the spout of the ladle does not changeposition during the casting in manual.

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PRINSID POURING TRUCK - HMI

TOUCH SCREEN PANEL

Mould management

On the screen there are ideograms of the containers, within which thecorresponding casting code is indicated. RED: the containers in red are containers inside which the machine hasalready cast. GREEN: the containers shown in green are those that are in the process ofcasting. 0000: the containers indicated by 0000 correspond to "do not cast"

In the central part of the screen there is a box with "Moulds in progress" withthe containers' character shown in RED or GREEN (if the machine hasalready casted or not) and the moulds that actually form that container(ONLY VERSION MULTIMOULD).

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PRINSID POURING TRUCK - HMI

TOUCH SCREEN PANEL

The pouring routin parameter:

Start Rise DegreesThis parameter expresses the angle that the ladle has at the end of acasting. It is the angle of the ladle between the cast and the other.

Multiplicator nominal speed xThis parameter is an indication of how many times the nominal castingspeed is multiplied before the metal is actually dropped into a mould.

Example: suppose we want to pour at a rate of 2 kg / sec. If the multiplier isset to 15 it means that the ladle, before actually pour the metal, rotates like ifit were to pour to 15x2 = 30 kg / sec. This parameter is useful to have a fastflow of metal at the beginning of the casting and, logically, to save time

Pour at multiplicator speed (kg)This parameter indicates the quantity of metal, in kg, that the machineshould pour with multiplied speed BEFORE switching to rated speed.

Permanence at multiplicator speed (sec)This parameter indicates how long the ladle, after pouring the amount ofmetal expressed in the previous point, remains at speeds multiplied.

Pause multiplicari/nominal speed (sec)This parameter indicates how long the ladle, after pouring at speedmultiplied, must stop BEFORE pours at nominal rated speed.

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PRINSID POURING TRUCK – HARDWARE – AXIS CONTROL

X AXISFOWARD - BACK

GEAR WITH SERVO MOTOR ASYNCHRONOUS SEW ENCODER BUILT-IN SEW MOTOR AXIS CONTROL CARD SEW

X AXIS

Axis to control andpositioning on the rails and

along the casting line

W AXISROTATION LADLE

GEAR WITH SERVO MOTOR BRUSHLESS SEW ENCODER BUILT-IN SEW MOTOR AXIS CONTROL CARD SEW

Y AXISLEFT – RIGHT LADLE

GEAR WITH SERVO MOTOR BRUSHLESS SEW ENCODER BUILT-IN SEW MOTOR AXIS CONTROL CARD SEW

Z AXISUP – DOWN LADLE

GEAR WITH SERVO MOTOR ASYNCHRONOUS SEW ENCODER BUILT-IN SEW MOTOR AXIS CONTROL CARD SEW

W , Y , Z AXIS

They are controlled by a CNprogram in order to

maintain the spout fixed inprogrammed positions

RACK FOR AXIS CARDS

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PRINSID POURING TRUCK – HARDWARE – PC E SOFTWARE

INDUSTRIAL PCwith WINDOWS

program inVISUAL BASIC

LOAD CELLS ELECTRONIC LOAD CELLS

AXIS RACKprogram

SIDAC CN

PYROMETER ELECTRONIC PYROMETER

The visual basic program controls the operation process.

The PC calls functions programmed in the axis rack.

Information of the external devices arrive to the PC (in particular the data of the weighingmachine), are processed and other functions contained in the axis rack are called (example:

cutting procedure at the end of the casting).

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PRINSID POURING TRUCK – HARDWARE – CONNETTIVITY

The machine is controlled by asoftware installed on an industrial

windows PC

Easy connectivity to network

Fast remote access

Fast control and rapid diagnostic

FIRM ROUTER INTERNET INTERNET PCM – PRINSID

SWITCH

INPUT – OUTPUT

PC TOUCH – PRINSID SOFTWARE

AXIS RACK SEW MOTION CARD

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PRINSID POURING TRUCK – WEIGHING SYSTEM

SUPPORT WEIGHED FRAME

REAR FRONT

FIXED FRAME

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Supports to isolate the operator cabin from weighed frame

Gearmotor X axisAttached to fixed frame

PRINSID POURING TRUCK – WEIGHING SYSTEM – PC E SOFTWARE

INDUSTRIAL PCwith WINDOWS

program inVISUAL BASIC

Processing through mathematicalfunctions of the weight values filteredthrough statistical functions.

LOAD CELLS ELECTRONIC LOAD CELLS

AXIS RACKprogram

SIDAC CN

Resolution up to 600.000

Serial port COM1: Rs232

25 Hz filtered sampling

2 mV/V

IP 67

from 500 to 2500 kg C3 OIML R60/2000 DE1-05.02

The visual basic program controls the operation process.

The PC calls functions programmed in the axis rack.

Information of the external devices arrive to the PC (in particular the data of the weighingmachine), are processed and other functions contained in the axis rack are called (example:

cutting procedure at the end of the casting).

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PRINSID POURING TRUCK – WEIGHING SYSTEM – DATA AND SIGNALS

PROCEDURES TO REMOVE EXTERNAL INTERFERENCE, VIBRATIONS ORSHAKINGS, TO WEIGHING SYSTEM, THAT ARISE FROM NORMAL

MECHANICAL OPERATION

IMPLEMENTATION OF

Filter for the environmentalconditions

IMPLEMENTATION OF

Statistical filter

IMPLEMENTATION OF

Estimation algorithm for endcasting

The shocks are eliminated by anincrease in the number of internalmeasurement cycles, or bylengthening the integration period.

During the casting phase, the weightvalues are stored, they are processedstatistically and the real speed of castingis calculated. The casting speed istransmitted to the PLC_CN

The data speed is updated from time totime and sent to the axes module for thedetermination of the exact moment of the

end casting.

Note: the statistical calculation of the actual casting speed takes place during a phase inwhich the machine moves with uniform motion in order not to introduce accelerations in

the system which might influence the values of the weights.

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PRINSID POURING TRUCK – WEIGHING SYSTEM – HMI

TARAThe weight of ladles withrefractory material must becontrolled and inserted into atable in order to have acorrect tare.

RECIPES TABLE

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Table machine parameters:

- Kg at the beginning of casting- Kg recorded at the end casting

Weighs

- Total weight detected by the cells

- Light weight material in ladles

LADLES LOAD PROCEDURE The moment you run the ladle load process the machine: 1. takes its total weight just before engaging 2. takes its total weight just after hooking 3. performs the difference between the weights: total weight - tare ARE KNOWN: 1. amount of metal in the ladle 2. pre-positioning position to the first mould to be cast

PRINSID POURING TRUCK - REFERENCES

6 INSTALLATION FROM 2011

Most important

Mexico Bulgary – 2 installations

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