Sand treatment processes are large consumers of electrical energy in many green sand mould-casting foundries. Only smelting plants use more energy. As a result of energy management policies in accordance with ISO 50001, the focus is on reducing energy consumption.
If the old motors are not to be replaced with energy-efficient ones at great expense, the only other solution is reducing idling phases. Observing idling phases more closely reveals phases of several minutes in which no sand is being transported in the individual plant components.
It is precisely in these phases that savings potentials can be unleashed by switching off these plant components. An intelligent querying function of the operating conditions at the moulding plant is always of primary importance, as this determines the sand requirement and sand output. While taking account of the various bunker fill levels, transport requirements can be determined at an early stage. Downtime at the moulding plant can therefore be planned in advance to avoid delays in production.
Depending on evaluation requirements, energy meters in the plant should be distributed in order to measure the actual consumption. The actual savings effects then become apparent in the ongoing evaluation by correlating total sand consumption and total energy consumption. If these values are continuously logged in a database at suitable intervals, comparative evaluations can also take place over longer time periods.
The method of implementation of the economy mode is part of the PLC control system which controls all actuators. The implementation of the required software makes sense if currently converting from an old to a new PLC system.