Brake discs ‘Made in Germany’ produced using a high-performance moulding system
The delivery of two large, identical ZFA-SD 6.5 moulding lines by Heinrich Wagner Sinto Maschinenfabrik (HWS) for the production of brake discs marks a significant step forward in the foundry industry. The key technical details and advantages of the moulding lines at a glance:
- Internal mould box dimensions: 1200 x 1200 mm
- Upper box height: 300 mm
- Lower box height: 250 mm
- Cycle time: 14.4 seconds
- Output: 250 complete moulds per hour
- Total floor area: Over 2,600 m² per plant
These are already the customer’s 7th and 8th moulding plants in operation worldwide.
Technical features and benefits of the HWS plants
Efficiency and flexibility
Models can be changed almost in cycle time via the moulding machine’s rotary table. If required, the cooling time can be extended by adding a further cooling chamber with 3 additional lines, bringing the total number of cooling lines to 9. Cooling takes place entirely within the moulding box, which increases efficiency.
High energy efficiency
The systems are characterised by high energy efficiency, as they utilise the latest electric motors in the current energy efficiency classes. All pushing movements are performed electrically to further reduce energy consumption.
User-friendly maintenance concept
A user-friendly maintenance concept has been developed which makes all hard-to-reach maintenance points accessible via platforms and walkways. Automatic lubrication systems are installed on the respective units to extend the service life of the racks and pinions.
Monitoring and software
The moulding lines are equipped with the latest HWS technology, including the well-known A.L.S. (plant control system) as well as an energy monitoring and cycle time analysis system. All systems are programmed in-house at HWS.
Production capacity and commissioning
Both moulding plants will be commissioned in 2025 and are designed for a total production of 210,000 tonnes of high-quality castings.
These high-performance moulding lines from HWS represent the latest state of the art in brake disc manufacturing and offer a combination of high efficiency, flexibility and ease of maintenance.