Foundry Automation Control Systems

foundry pourRevere Control Systems has been designing and integrating automation systems for the foundry industry for more than 30 years. A foundry is a factory used for metal casting production, which is the process of pouring liquid metal into a mold and allowing it to solidify. This type of production requires a high degree of technical precision. We help identify opportunities for improvement and implement effective solutions across all aspects of foundry operations.

Automated Foundry Operations

  • Melting: Experience with electric arc furnace (EAF), induction, cupola furnace and crucible techniques.
  • Degassing: Knowledge of the importance of removing hydrogen gas from aluminum pouring.
  • Mold-making: Experience with sand casting, lost-foam casting, investment casting, ceramic mold casting, V-process (vacuum), die casting and billet casting (ingot).
  • Pouring & Shakeout: These processes constitute the heart of a foundry, using pouring done with gravity or assisted with vacuum or pressurized gas; and removing solidified metal from the mold.
  • Degating: The removal of heads, runners, gates and risers from the casting.
  • Heat Treatments & Surface Cleaning: Processes to alter the physical and chemical properties of a metal, which include annealing, case hardening, precipitation strengthening, tempering and quenching.
  • Finishing Processes: Experience with surface cleaning, grinding, sanding and machining.

Automated Foundry Projects

The below are examples of typical projects we've completed.

Mold Line Relocation

We provided all automation and control systems associated with relocating a foundry mold line, including the sand system, pour furnace, shot-blast cabinets and conveyors. Network information includes parts profile information and interlocks pertaining to castings being passed from one station to another. An operator selects the part numbers to be run during a shift, and the profile information is downloaded to each PLC station in coordination with the part reaching that station. Shift reports are automatically generated, while other production data is available as needed.

Iron Melting Cupola Renovation

We provided a fully integrated instrumentation and control system for a renovated cupola and associated emission control equipment. Major equipment under control consisted of windbox, carbon monoxide afterburner, recuperative heat exchanger, primary and secondary water quench injectors and baghouse. We handled the system design, selection of control hardware and software, configuration programming, fabrication of panels and enclosures, installation, field supervision for the electrical construction and startup services.