C O AT I N G S F I LT R AT I O N F E E D I N G S YS T E M S M E LT S H O P R E F R A C TO R I E S M E TA L L U R G I C A L A N D P O U R I N G C O N T R O L S YS T E M S B I N D E R S C R U C I B L E S

UCERAMAUTOMATIC POURING WITH STOPPER ROD

nPredictive control

nOperator safety

nPouring consistency

nTracebility and process control

nRobust design

nCasting Yield and Casting quality

Offers the state of the art automation to your new or existing pouring unit, in order to reach :nThe right quantitynAt the right temperaturenAt the right waynAt the right time

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UCERAM Concept

UCERAM Concept The moulds absorption curve

The predictive logicThe predictive control concept of UCERAM software is the result of 30 years of experience in mould pouring. UCERAM runs to fill up the moulds in order to minimize actions and tuning of the operator. The system measures and adapts itself to the drifts that occur during the pouring process, particularly around the stopper and nozzle. Thus, the system learns and builds the ideal pouring law of each pattern, point after point (called the model). This model is automatically input as the setpoint for the next mould to pour.Therefore UCERAM anticipates the coming variations before they occur (as in a rally car, the co-pilot helps the pilot to anticipate his actions).

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UCERAM Concept

*only for moulds designed for choking **too low cast iron in the cup

Performance AssessmentDefined according to the process to be equipped and FOSECO’s expertise. Typically:

Performance index UCERAM targeted performancesOperational availability (O.A.) Over 99.5%

% of moulds poured in automatic (P.M.A.)

Over 95%

Operator involvement (O.I.) O.I. global = less than 2% of the moulds poured in automatic are subject to a parameter adjustment by the operator.O.I. in long series (> 300 molds)= less than 1% of the moulds poured in automatic are subject to a parameter adjustment by the operator.

Final level in the cup measured in mm from the top of the mould

Can be tuned by the set point parameter to adjust final level in cup.Mean deviation measured by the camera sensor: +/- 8 mm around the mean end level.

Pouring time At least as fast as an operator can do in the same conditions of choking and end level management. The system will try to reach the time given by the moulding line without introduction of lead time.

Choking* (saturation) Over 95% of the moulds are poured without loss of choke from choking start to end of pouring

Time to reach choking* Over 95% of moulds reach choking before expected time recorded as parameter in the database

Short pours** Less than 1/1000 as an average

UCERAM Performance TrackingUCERAM provides a daily report (excel file type) of the pouring database with a statistical analysis of each tracked parameter* for each pattern sequence. Each daily report can be easily added to the previous one for extended period analysis.* parameters followed by UCERAM such as pouring time, end of level in cup, temperature, inoculation rate, poured weight in mould, etc... „

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Basic Components: OPTO-ASOptical Camera Sensor Technology - the pouring camera

For horizontal moulding linesn1 OPTOAS - MF at pouring position

Main BenefitsPouring camera (OPTOAS-MF) : multi measurement sensor nDetects level in cupnMeasures stream sizenDetects stream appearance (including leakage)nChecks alignment of stream and mould cup to

pournNo modification of pouring cup requirednRemote view of the cup on monitor

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Basic Components: OPTO-ASOptical Camera Sensor Technology - the post pouring camera

For vertical moulding linesn1 OPTOAS - MF at pouring positionn1 OPTOAS - TW at post-pouring position

Main BenefitsPost pouring camera (OPTOAS-TW)nIncreases line speed (zero delay between stopper

closure and line push)nMeasures final level in pouring cupnSettings versatile with mould thickness variationsnPossibility of adding more post-pouring cameras

all along the moulding line

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DEM9M actuatornBrushless motorn100% electric, 13 kg weightnAll in line with MQS120M

Basic Components: DEM9M / MQS120MActuator and Stopper Mechanism

MQS120M mechanism : the guiding systemnVery high precision guiding, using ball bearingnAnti-locked designnUltra low maintenance

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ARM equipped with TWISTER & PLUNGER & stopper fixing partsnTwister to reduce slag accumulation between

stopper and nozzlenPlunger to clean up slag through the nozzle

(recommended for ductile or compacted graphite iron)

nEasy alignment with the nozzle

Stopper rod fixing partsnFast replacement of stopper rod

Main BenefitsnMore than 1,000 units installed worldwide (steel

& foundry plants)nMulti control facility (position, speed, strength)nPrecise stopper positioning (accuracy 0.1 mm)nHigh speed : up to 150 mm/s for fast closurenFast reaction time (15 ms) for better flow controln“0” flow position of the stopper recalculated after

each pouringn“Soft landing” function to protect stopper &

nozzlenPossibility to open/close manually with a lever rodnLong life high temperature sealing & greasing (no

dust contamination inside)nUltra low maintenancenAll in rack concept for easy access of all equipment

Basic Components: Horizontal arm and stopper rod features

Operator Pulpit: Bulk

Electric cabinetn Smart controller, PLC basedn Siemens as a standardn Possibility to implement other brands

(Alen Bradley, Schneider Telemecanique, Mitsubishi)

Operator Pulpit: Pendant Box Monobloc

Basic Components: Control panel & interface unit

Operator Pulpitn Control panel, industrial PC & HMIn Customised design available

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Basic Components: Control panel & interface unit

Human Machine Interface

Human Machine InterfacenHuman Machine InterfacenSynoptic of pouring deck on livenReal time messages/Alarm displaynAccess to results & settingsnLive videos from camera sensorsnGraphs and moulds mapping on livenRecord of pouring sequence > 1 yearnAllows pre-pour function (anticipates pouring

during the push sequence)

Main BenefitsnUser friendly interfacenReduced operator involvementnReady for up-gradenWindows SQL for easy data downloadnRemote access available via internet nReduces pouring time for productivity improvementnMinimizes dispersion on final level of iron in the

cup for yield optimization

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Additional Equipment

Pressurised Pouring FurnacenControl of the metal level in the pouring channel

(LASERNUM ) nHot metal detector (HMD-A ) to inform when

re-filling and pneumatic circuit (PRESSTROL )

Vertical Flaskless Moulding LinesnPositionning sensor (MAGECOD): automatically

records the position of each cup to pour and adapts the nozzle over the cup to pour, without missing any cup when pattern changes.

Bottom Pouring Ladle & Turn-key engineeringnLadles (0.5 to 4.0 tons capacity)

nPositioning Platform

nTransfer Ladle Loader

together allow the full monitoring of the pressurized pouring furnace even during re-filling. MAGECOD sensor

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Inoculation PracticenInoculant Feeders (INOFEED, MSI - Metal System Inoculant)

UCERAM Flow

evaluator

Options (stand alone or connected with UCERAM)

Dynamic inoculation (UCERAM+INOFEED+INOCHECK)

Main benefitsnFriendly HMI, even for stand alone solutionsnReliablenOptimized consumption of inoculantnAuto-alignment of feeding pipe nNo contamination by not or badly inoculated

castings

Temperature MeasurementnIn-stream temperature management

(TEMPSTREAM)

nIn-depth continuous temperature management (ACCUMETRIX*)

nInoculation control (INOCHECK)

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C O M M I T T E D T O F O U N D R I E S

*FOSECO, the Logo, ACCUMETRIX,CRITERION, INOCULIN, KALTEK, TRIAD, CRITERION and VAPEX are trade marks of the Vesuvius Group, registered in certain countries, used under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder or as expressly permitted by law. Applications for permission shall be made to the publisher at the address mentioned. Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein are published as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation. The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale available on request.© Foseco International Limited 05/11.

Foseco International LimitedDrayton Manor Business Park,Tamworth, Staffordshire,England B78 3TLPhone: +44 (0)1827 262021 Fax: +44 (0)1827 283725 www.foseco.comPlease contact your local Foseco team

Service and Ancillaries

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Savings items

Example of saving simulation, in €/tonneServicenAll in rack concept (main components & opinions)

for easy accessnLocal language availablenUCERAM and its ancillaries are guaranteed 2 yearsnSpare parts are available for 10 years minimum

from the date of purchasenAssistance contract availablenRemote access to internet via teamviewer nTroubleshooting nContact via local FOSECO team

Associated consumablesnStopper and Nozzle (VAPEX* technology)nLining for bottom pouring ladle (KALTEK* ISO)nLining for furnacesn Inoculants (INOCULIN* 900)

Economic value for customersnDesigned by our Flow Control specialists, our model

evaluates the savings for customer achievable with our solutions

Consumables (metallurgy)

11% Consumables (pouring + cores)

6%

Refractories2%

Cleaning5%

Energy37%

Rejections26%

Labor9%

process depreciation

4%

VAPEX stoppers and

nozzles

Dense (TRIAD*, CRITERION*)

and Insulating (KALTEK) linings

Inoculants