In the metallurgical industry, especially in foundries, precise temperature control of liquid metal is crucial to ensure high quality castings. Electrically heated transport vats play an extremely important role here, enabling the safe and efficient handling of liquid aluminum alloys. In our case study, learn how advanced automation and temperature control solutions can significantly improve production processes, reduce operating costs and increase energy efficiency. Read on and discover how to optimize liquid metal handling in your foundry and ensure the highest product quality!
Transport vats play an important role in the metallurgical industry, especially in foundries, where they are used to transport liquid aluminum alloys. They make it possible to safely move liquid metal from furnaces to various points of use, such as holding furnaces, casting machines, sand molds or ingot moulds. Their design ensures that the right temperature of the metal is maintained, which is essential for further production processes. Transporting liquid aluminum requires well-insulated vats with heating systems to prevent the metal from cooling down. These vats are mobile and can be easily moved around the production facility. Maintaining the proper temperature of liquid aluminum is crucial to maintaining its physical and chemical properties, which directly affects the quality of the final product. Precise temperature control ensures the homogeneity and stability of the metal, which prevents defects and a reduction in casting quality. Failure to monitor this variable can lead to overheating or underheating of the metal, resulting in defects, material loss and the need for additional machining. In addition, effective temperature management minimizes energy consumption, reducing production costs and increasing the energy efficiency of the entire process, which is both economically and environmentally beneficial.
Electric heated transport vats consist of the following main components:
A customer in the foundry industry approached us with a problem of maintaining the proper temperature of liquid aluminum in a transport vat. In order to guarantee the high quality of the final product, it was necessary to effectively heat the vat to prevent the metal from cooling during transport. The customer struggled to maintain a stable temperature during transport from the time it left the furnace until it reached various points of use, which required a monitoring and control system to maintain optimal conditions.
In addition, the client wanted to control operating costs by monitoring the energy used to heat the vats. Accurate measurement allowed for the identification and elimination of excess expenditures, resulting in savings and improved efficiency throughout the process. Reducing operating costs and minimizing environmental impact were key to the company's sustainability.
Transport vat
To meet the customer's requirements, we came up with a comprehensive solution that effectively maintains the proper temperature of the liquid aluminum alloy and monitors energy consumption. We started with the JUMO DICON touch PID controller, which we installed in a central control cabinet. With an intuitive touch screen, operators can easily monitor and control the temperature of the metal. A thermocouple mounted in the heating lid of the ladle precisely measures the temperature of the aluminum, and the controller automatically adjusts the heating parameters to ensure the optimal temperature of the melt.
We then implemented aJUMO TYA 203thyristor power controller, which we installed next to the regulator. This device controls a three-phase transformer that supplies the silicon carbide (SiC) heating elements in the heating cover of the transport vat. The JUMO TYA 203 controller precisely regulates power, protecting the heating elements from overload and ensuring even heat distribution. Installation and commissioning went smoothly with the pre-configuration of both units.
Monitoring energy consumption was one of the customer's requirements. The JUMO DICON touch process controller fulfills this function. It records operating hours and energy consumption, allowing the customer to accurately track consumption and optimize it. With this solution, the customer was able to significantly reduce operating costs and increase the energy efficiency of the entire production process.
JUMO TYA 203
JUMO DICON Touch
The introduction of an advanced automation and temperature control system brought numerous benefits to a foundry customer. With systems and solutions from a single source, the customer could count on full system compatibility, simplification of the purchasing and service process and a permanent contact person for technical support. The pre-configured JUMO DICON touch controller, tailored to the specific needs of the application, enabled the system to be put into operation quickly without complex calibration, operating on a plug-and-play basis. The proportional control (P) in the JUMO TYA 203 power controller effectively protected the heating elements from overload, increasing their life and reliability. In addition, precise temperature control and monitoring of energy consumption helped optimize operating costs, increase energy efficiency and improve the quality of the final product. All this meant that the customer was able to significantly increase the efficiency of its production processes and achieve significant savings.
My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.
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