威尼斯Late in-stream inoculation can virtually lead to elimination of the fading effect but conventionally inoculation systems often are unable to address some common sources of variations. The ITACA Stream™ inoculation system has been developed to consider these situations and give higher precision in the inoculation process.

ITACA Stream™ inoculation system

ITACA Stream™ inoculation system has been developed together with European foundries to inoculate cast iron with higher precision compared to conventional units. The starting point during the development was a conventional screw feeding mechanism with high accuracy and dependability similar to those used in most inoculation units, but that is where the similarities ended. The outcome of the development is a solution that is able to consider some of the most common caused of inaccuracy on conventional units. The fact that they cannot adapt to the varying conditions that happens daily in a foundry. These conditions are variations in nucleation, mismatch of the inoculation and the iron stream and variations in pouring time.

Nucleation level

Over inoculation is an increasing issue in foundries and is often caused by underestimation the effect of the inoculation. The root cause of this situation is essentially a lack of information of how the need for inoculation varies the foundry. The quick-fix applied by many foundries when facing cementite etc is to increase the inoculation but a 威尼斯 efficient way is to introduce an inoculation rate as a function of the nucleation status of the iron. This is possible trough integration with ITACAX™ and replaces operator dependent rule of thumbs and traditional wedge tests and provides a vast amount of previously unknown information to the foundry. Since this approach is also a way to increase the automation in the foundry it has also other advantages beyond the obvious once.

Misalignment

A common source of variation in the inoculation process is the mismatch between the flow of inoculation and the stream of iron. This situation often leads to an underestimation of the effectiveness of the inoculation with increasing amounts as a consequence. Sand contamination is another common negative effect of mismatch since the excess inoculation may be mixed with the return sand. To counter this situation we have fitted ITACA Stream with a brushless motor with high precision that makes it possible to rotate the outlet pipe in position. The same feature can also be automated trough ITACA Vision. This makes also the inoculation process in line with our philosophy of reducing the effect of manual operations in the foundry.

Pouring time

The pouring time is a critical factor with stream inoculation. If a specific percentage of inoculation should be added to a casting the pouring time also needs to be fixed or be measured. In ITACA Stream this can be taken care of in two ways, 1) measuring the pouring time trough ITACA Vision or 2) using the pouring time measured by an external system. An example of an external system are those produced by Pour-tech, for automatic pouring. If the pouring time varies with a constant flow rate of inoculation, as with most inoculation systems, the inoculation level will not be constant. ITACA Stream uses a variable flow rate in function of the pouring time to ensure the inoculation is consistent and traceable.

Key benefits of ITACA Stream™ In-stream inoculation system:

  • FLEXIBILITY: ITACA Stream™ In-stream inoculation system is equipped of two tanks; one in production and one ready to change
  • HIGH EFFICIENCY: Optimal distribution and uniform inoculant for each casting & continuous monitoring of the process
  • DIMENSION: Small dimensions and can be adapted to areas where space is restricted
  • COMPATIBILITY: Compatible with both modern and older pouring systems
  • COM威尼斯CATION: Communicate with PLC’s via PROFINET to receive required information (like the stopper movements)
  • SAND CONTAMINATION: Prevents sand contamination during operation and change of inoculant
  • MAINTENANCE: Automatic cleaning system removes remaining inoculant in the feeding system when switching to the next tank. The unit is pressurized to avoid dust and small particles of inoculant on the inside
  • SAFETY: Improved working conditions thanks to automated dosing
  • INTEGRATION: Combined and integrated with ITACAX™. When nucleation status is measured in the iron the amount of inoculant required can be automatically derived from cast iron thermal analysis

Are you looking for a customized inoculation application? Speak with us and we will find a solution.