Foundry Rollover Draw
Foundry Rollover Draw Machines
Del Sol provides for custom solutions for your foundry rollover / draw needs. From rotary units, to side discharge, to pass through...our custom built rollovers can be configured to your exact plant requirements.
Some examples are...
Large Custom Core Box Rollover Machine
100% Electric NO PIT is fundamental to our design.
ROLLOVER / DRAW FOR NO BAKE MOLDING
Any size you need is available, but on larger sizes, pits may be required.
Model 1 Typical Sizing is shown below.
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Max Pattern Width – 36”
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Max Pattern Length – 48”
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Max Pattern Height – 18”
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Minimum Daylight – 10”
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Max Opening (Daylight) – 42”
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Nominal Max Mold Size – 36” Wide X 48” Long x 12” Tall
Model 2 Typical Sizing is shown below.
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Max Pattern Width – 52”
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Max Pattern Length – 64”
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Max Pattern Height – 25”
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Minimum Daylight – 10”
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Max Opening (Daylight) – 55.5”
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Nominal Max Mold Size – 48” Wide X 60” Long x 24” Tall
DESIGN PRINCIPLES
Del Sol strives for simplicity of design and ease of maintainability. To this end, we have developed our version of the rollover draw machine to be minimally invasive on installation with a primary goal of not having pits for most installations. Further, we have sought an extremely simple set of components for primary motions that are readily available in the U.S. supply chain. We realize that foundry maintenance departments are not as big as they used to be, and that it is hard to find maintenance personnel. For these units, we have tried to reduce the sophistication of skills needed to make it a simpler and more robust unit to work on than “traditional” designs.
"LOOK MOM, NO LEAKS!!!"
100% Electrical Operation eliminates hydraulic leaks, hydraulic rebuilds, adjustments to pressure and flows over time, and specialized hydraulic controls knowledge. Plus, parts availability. Gone are the days of replacement hydraulic components on the shelf so we eliminated the need.
BASIC CONSTRUCTION AND SIZING
Del Sol’s rollover draw features a unibody plate steel frame fabricated for ultimate rigidity from ¾” plasma cut steel and stiffened throughout. The rotating frame is supported by two oversized slewing rings that serve the function of both support and rotation. This design eliminates the need for wheels, external machining, and sand covered chain and sprocket drive systems. The rotational slewing rings are half way up the machine keeping them out of the sand.The base is also fabricated from CNC plasma cut steel for tolerance control and bolts to a flat floor. The design needs minimal foundation and a solid 6” concrete floor is plenty as there is not torsional load mandating a heavy foundation.
FIXED WIDTH PATTERN CLAMP
Our standard rollover design features fixed width pattern clamping. Your pattern will be mounted to a fixed width plywood or metal bottom board or bolster. The rollover has guides fitted around the super duty pattern conveyor to guide the pattern to keep it straight and also hold the pattern when the unit turns over. Once the pattern is in place within the rollover, a pneumatic lift table that also holds the extraction vibrator is engaged to hold the pattern in place. This same clamp bar arrangement is used to ensure that the force from the vibrator is most fully transmitted into the pattern box at time of extraction.
Variable width clamping is available as an option.
MOLD CLAMPING METHOD
Once the mold box is in and clamped, the moving platen of conveyor is lowered to the mold box. The mechanism features a high tolerance die set and two heavy duty ball screws driven by two three phase motors. Within our controls structure, we monitor that feedback of torque and power going to the two Variable Frequency Drives (VFD’s) that control the ball screws. The VFD’s are adjusted 40,000 times per second to balance applied power between the ball screws to assure balanced movement and clamping pressure. The conveyor is moved to meet the mold box / bottom board until snug.
ROLL METHOD
The primary frame is rotated using a 7.5 horsepower 3 phase electric motor controlled via VFD. The motor is coupled to an 850:1 reduction gearbox which is then coupled to the rotating frame. There are no chains or chain connection points to break, tension, or repair. Four proximity switches define rotational position and control roll speeds. The unit starts its roll gently accelerated to high speed until a slow down proximity switch is triggered, then the VFD decelerates the unit to a gentle stop at the rolled over position mechanical stop (adjustable). Using a VFD, we can control speed, accel, decel, and applied power to match process requirements.
DRAW
Once in the draw position, the extraction vibrator (3 phase with mechanically adjustable force) is engaged, then a slow speed clamp open process is engaged. The operator can clamp and unclamp at low speed until the mold drops from the box at which time high speed draw is engaged to full open.
Molds are stripped onto a heavy duty roller high conveyor. The roller high conveyor lets you use any flat bottom board type to care to. No special discharge bolsters are needed. We can also use a heavy duty belt conveyor in lieu of a bottom board if desired.
Once the mold is discharged from the unit, the rotation is reversed to home, the pattern is unclamped and ejected, and the next pattern is brought in.
STANDARD CONTROLS
The base price includes a pedestal for the operator to manually control all functions as this is the way most rollovers end up being operated. We can, as an option, quote fully automated controls which includes laser sensors to sense when a mold has dropped and position sensors for each rollover function.
Our control panel includes a flanged disconnect, 120 VAC control transformer, roll VFD, clamp VFD’s, reversing motor starters for conveyors, motor starter for extraction vibrator, and the necessary i/o for positioning controls. The unit features an Allen Bradly Micrologix processor for interlocks and ladder logic. We use a robust Allen Bradley touchscreen HMI.
UTILITIES REQUIRED
480V 3 Phase – 60 Amp Panel
Compressed Air 90 PSI @ 5 cfm