Extension of the production with aSEIATSU-Moulding plant EFA-SD 6at Fritz Winter in Stadtallendorf

The company Fritz Winter produces engine-and automotive castings for internationalmanufacturers.

With a annual production of 360.000 tonsFritz Winter ranks among the most importantcompanies in this branch.

In the middle of october 2003 Fritz WinterEisengießerei GmbH & Co. KG started theextension of production of brake disks for carsin the new foundry G7.

The heart is the new SEIATSU-Moulding plantfrom Heinrich Wagner Sinto (HWS) in Bad Laas-phe and was designed with the following out-put parameters:

Characteristics of the new SEIATSU-Moulding plant

■ Moulding box size:1120 x 1080 mm Drag 250mm, Cope 350 mm.

■ Output:250 complete moulds/h.

■ Single- as well as double push in the coresetting line and in the pouring line.

■ Brake disks are poured in a horizontal posi-tion.

■ A very even structure and a reduced porosi-ty of the castings are reached.

■ Very high dimensional accuracy of the cas-tings and minimization of mismatch inmould.

■ The pattern change can be executedwithout loss of time in the cycle of themoulding machine.

■ Automatic separation of the return scrap ofcastings.

Modern software to optimize

the availability of the plant

For the first time the software C.A.S. (cycletime analysis system) which was developped atHWS is used at the moulding plant. C.A.S.2010is a recommendable aid for a plant with theabove mentioned output, for the control of thecomplete plant regarding the temporal courseand to control each of the approx. 300 driveswith regard to the desired and actual operationtimes as well as to secure or to increase theavailability of the plant.This system determinesthe starting time and the duration of the mou-vement of each cycle of the plant and of eachdrive by PC. This is saved in a XML- file structu-re and therefore is available graphically or intabular form to the operator for optimization.

Modern electric drivesat pushing units

An further technical development is the use ofelectric drives at pushing units in the core set-ting-, pouring- and cooling lines. Field orien-ted, regulated asynchronous machines areused, in which the appropriate pushing- anddamping units communicate with each otherby a guiding frequency.

Typical of the electric drives installed by HWSis the extremely precise variability. This is rea-ched because there are no longer disturbances,like fluctuations of oil temperature as well as oilpressure and compressibility of the oil column.Further advantages are the reduction of thefire risk and pollution of environment causedfor example by oil leaks and filter change.

Regarding the economic advantages the ener-gy balance of the electric drive is convincingbecause surplus brake energy at the existingrecovery unit can be brought back to the net-work and the power losses which occur in theelectric lines are considerably lower than thelosses of flow of the hydraulic system. Theenergy consumption of the electric drives isaround 50 – 70 % compared to other hydraulicdrives.

First HWS-Moulding plantdelivered to Fritz Winter in 1993

In 1993 the company Fritz Winter already pur-chased the first HWS-Moulding plant with two single moulding machines of the type „EFA-SD 4“ for the production of engine blocks.

Moulding box size: 930 x 710 x 360/300

Output: 200 complete moulds/h

Due to the positive experiences and resultswith this plant Fritz Winter decided to buy asecond moulding plant from HWS, a twin-typemouldimg plant „ZFA-SD 4,5“ for the fabrica-tion of brakes and hydraulic castings, in 1998.

Moulding box size: 850 x 850 x 220 / 400 x400/220 (can be used reversible)

Output: 220 complete moulds/h

This is now the third SEIATSU-Moulding plantmit two single moulding machines, type EFA-SD 6, moulding box size:

1120 x 1080 x 350/250 mm,

output: 250 complete moulds/h.

According to the operator it produces to theirfull satisfaction regarding all expected results ofthe output and quality of the castings. The co-operation during planning, erection, commis-sioning and technical support can be described,without exaggeration, as exemplary. With oneof the most efficient and technological pro-gressive moulding plants together with coresetting robot, automatic pouring furnace, casting-sand-separation including cooling, shot blasting and fettling of the castings Fritz Winter is prepared very well for the futu-re.

Signal flow of the speed/torque control at the absolute postioning Source: Lenze, servo-positioning

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