Michenfelder Elektrotechnik GmbH & Co. KG

An der Fahrt 4, 55124 Mainz
Germany
Telephone +49 6131 19017-0
Fax +49 6131 91017-17
info@michenfelder.com

Hall map

GIFA 2019 hall map (Hall 16): stand G23

Fairground map

GIFA 2019 fairground map: Hall 16

Our range of products

Product categories

  • 07  Moulding sand preparation and sand reclamation
  • 07.01  Moulding sand preparation
  • 07.01.05  Measuring and control equipment for moulding sand preparation

Measuring and control equipment for moulding sand preparation

  • 18  Control systems
  • 18.02  Control equipment, automation technology

Control equipment, automation technology

  • 19  Measurement and test technology
  • 19.05  Mould and moulding sand testing
  • 19.05.02  Moulding sand testing equipment

Moulding sand testing equipment

  • 19  Measurement and test technology
  • 19.06  Quality control

Quality control

  • 24  Information processing
  • 24.04  Software for business and process data capture

Software for business and process data capture

  • 24  Information processing
  • 24.05  Quality assurance software

Quality assurance software

Our products

Product category: Consulting, design, service and engineering

Moisture measuring and control systems for green sand mixers

Over 50 years of experience with measurement inside mixers
The incomparably high reproducibility of material output moisture within very close limits is possible only by continuous measurement inside the mixer. As only in the mixer
all moulding sand components, like sand, additives and water are combined, it is possible only in the mixer to obtain a representative and precise determination of the moisture. The sand moisture is monitored without interruption right from the moment the material enters the mixer until it is emptied and is maintained automatically with a minimum of fluctuations on the desired level.

With a reliability and a preciseness no other system can offer, the MICOMP 5 Type G-CH unit converts fully automatically a fluctuating entry moisture level into a consistent output moisture level.

The system can be installed subsequently in an existing plant simply and with proven great success and without any noticeable interruptions of production. Nearly all commercial batch mixers, but also continuous mixers, can be fitted with the system.

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Product category: Consulting, design, service and engineering

Moisture measuring and control systems for sand coolers

Cooler turned into a sand regenerator
Equipped with a moisture measuring and control system a cooler becomes a sand
regenerator.

Optimum sand reconditioning commences in the sand cooler
Properly prepared well-flowing moulding sand at the moulding machine and short cycle times are two important and typical requirements
of modern sand casting production. For good regeneration of the used sand and consistent moulding sand quality at the moulding machine not only a good cooling effect is indispensable, but also sufficient pre-moisturising and a sufficiently long dwell time in the downstream used sand hopper.
Maximum moisture with maximum accuracy – with no fear of over-moisturising
The moisture of the sand conveyed from the cooler to the used sand hopper, should amount, at least, to 2.0 to 2.2% H2O (better more). The importance of this will be explained in the following chapter.
When hoppers and conveyor belts are in optimum condition, some foundries will even operate with ideal 2.8 to 3.0% H2O, which at the same time is affecting the cooling performance positively. A basic prerequisite for this is a reliable moisture measuring and control system, like the MICOMP series, which will convert a fluctuating input moisture level into a consistent output moisture level within very close fluctuation limits. The often met procedure in foundries to operate the process with too dry sand coming out of the cooler as a precaution, because fearing the consequences of over-moisturization, and thereby to tolerate inferior sand quality and higher temperatures is typical for other moisture measurement systems. Such a compromise is no longer necessary with the Michenfelder system. The system is keeping the fluctuation margin at the cooler exit to incomparably low ±0.05 to 0.2%*.

 

Experience and the advanced technology of continuous moisture measurement inside the cooler are the determining factors. 500 – 600 mixer-coolers of all commercial makes have already been equipped with great success. The system is setting the standard since many years.

*1st Standard deviation
Users of fluid bed coolers know the problem well:
Extreme fluctuations of output moisture occur in many production periods, particularly after work breaks or plant standstill
and result in quality deterioration of the moulding sand and of the casting itself. Casting scrap caused by this kind of difficulties does not need to happen. The moisture measuring and control system by Michenfelder ensures across all production periods fully automatically and reliably precisely and sufficiently moisturised moulding sand – and this also when the sand is cold and dry at the start of production or after breaks.
Property-decisive fine dust parts remain in the system
Typical occasions, when other systems fail, for instance with cold (at shift start), very hot or sand from non-cast moulds
are handled by the MICOMP 5 Type G-FBK unit in a targeted manner. In this way, property-determining fine dust parts remain in the sand. Hence, the system provides ideal conditions for early dispersing of the bentonite in the downstream used sand hopper.
Water addition which is only temperature controlled is not sufficient
The installation of a moisture control which is solely based on the temperature of the moulding sand is no reliable solution,
because there are too many critical situations in the production process which remain unconsidered. In case of cold, dry sand, for instance, a solely temperature-based moisture control system would add no water at all (for instance at production start on Monday morning). In such a case the exhaust air system would extract important finedust components, changing the sand characteristics, which again would affect gravely the quality of the casting.
Top solution for batch type coolers
With MICOMP 5 Type G-CHC Michenfelder is providing a system which will provide a highly precise output moisture even in case of widely fluctuating input parameters and considerable amounts of required cooling and moisturising water.

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Product category: Consulting, design, service and engineering

Online sand testing systems

Where should the compactability of the moulding sand be consistent – at the mixer or at moulding machine?
On the transportation route from the mixer to the moulding plant there is a large number of external influences and of internal reactions subsequent to the mixing process, affecting the sand. These influence the compactability with always different intensity, until it arrives at the moulding plant. The answer to the question where the compactability of the sand really matters can only be: At the moulding plant! Though it is obvious that for this, the compactability must be determined also at the moulding machine (and not at the mixer),
we do know that very often the question is put why just Michenfelder is so far the only manufacturer who succeeded to master this challenging task.

 

We are pleased to explain why this location of the sand testing system is exactly the right one and that the measurement there is not belated at all and why controlling the compactability with Michenfelder does work so extraordinarily well and that consistent results directly at the moulding machine can be guaranteed.

 

The key to success is interlinking and control-technical coupling of the sand testing system at the moulding machine with the continuous moisture control system with super-fine resolution at the green sand mixer. As moisture and compactability correlate, this system is in the control concept, as a finely reacting adjusting device, of dominant importance.

 

The moisture measuring and control system already ensures, because of the correlating behaviour of moisture and compactability, pre-stabilisation of compactability.

 

When now the sand composition changes the system registers the smallest deviations from the set compactability value and adjusts by feedback to the moisture measuring and control system in the mixer permanently and in finest steps the required water amount to the slowly changing sand composition maintaining automatically the compactability at the moulding machine on a constant level.

 

Beyond that, the various changes occurring in the sand when conveyed from the mixer to the moulding machine, due to follow-up saturation of the bentonite, evaporation and temperature effects, varying dwell times, sand aerators and conveying belt transfer points can, till today, only be registered fully automatically and reliably offset by this particular arrangement and interlinking of the modules of the Moulding Sand Management System FoMaSys.

 

By means of this system arrangement it is possible to warrant across all production phases an extremely narrow fluctuation range of compactability of s = ± 2% directly at the moulding machine. With reliably and sufficiently pre-moisturised used sand this system arrangement produced during daily routine consistently a standard deviation which, with s = ± 0.8 – 1.5%, is still much better. No other system can achieve this. For the capability of a modern foundry to operate with regard to sand with permanently low scrap rates, it is thus of critical importance at which point in the process of reconditioning the moulding sand possesses consistently the best mechanical properties. This point is not the mixer, but the moulding machine.
Process-integrated moulding sand management directly at the moulding machine
There is a choice of two different on-line sand testing systems. The proven VEDIMAT, with which the compactability and the green compression strength are determined and the brand-new ONLINE-SANDLAB (currently still in the internal pilot period).

New ONLINE-SANDLAB with wide range of measured variables and, for the first time, process-integrated permeability testing
During the Moulding Material Conference (Formstofftage) at Duisburg, Germany, in February 2014, the prototype of the new ONLINE-SANDLAB with process-integrated permeability measurement was presented for the first time
With this new ONLINE-SANDLAB Michenfelder (r)evolutionises the monitoring and control of moulding material parameters and complements the modular Moulding Sand Management System FoMaSys. In a compact automatic testing unit for conveyor belt installation there are several devices combined for the determination of a so far unequalled multitude of quality-relevant variables for sand preparation. For the first time, also permeability testing has been relocated away from the laboratory into the sand preparation process. This relocation allows action and reaction based on an enormously enlarged and directly at the moulding plant generated database in real time.
Measured variables and functions
The following measured variables and functions are available when using the sand testing systems VEDIMAT and SANDLAB
(VEDIMAT = V / SANDLAB = S)

 

With stand-alone operation:

  • Compactability V,S
  • Shear strength S
  • Compression strength V,S
  • Permeability S
  • Moisture and temperature S
In combination with process control system MiPro:

  • Shear strength with record of deformability graph S
  • Compression strength with record of compression strength drop graphV,S
  • Content of fines V,S
  • Bentonite equivalent S
  • Use of comfortable monitoring, analysing and evaluation tools V,S
  • Remote maintenance for rapid error analysis or measured-data evaluation V,S
When connected to moisture measuring and control system in the mixer:

  • Fully automatic control and stabilisation of compactability directly at the moulding machine V,S
  • Profit from use of two independent systems, complementing each other perfectly V,S
  • Use of the Moulding Sand Matrix – the navigation system for sand reconditioning V,S

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About us

Company details

Michenfelder is a pioneer and forerunner of many well-established processes
for measuring and controlling important sand parameters and is today the supplier of
the process- technically leading Moulding Sand Management System
for green sand conditioning

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