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ASIMCO Camshaft (Yizheng) Co., Ltd.
Cost-Reduction and Improvement Case — Sand-Removal Modification of the Floor Rail Base Plate on Line B
Release Date:
19-03-01
During the molding process on Casting Line B, sand drops and fragments of the sand mold shell inevitably fall onto the floor, leading to significant accumulations of waste sand on the base plate. This not only results in material waste but also makes the line dirty and disorganized, thereby negatively impacting production. Initially, the solution was to install two rotating brush heads driven by motors to sweep the base plate; however, practical experience revealed that this approach was largely ineffective. The soft brush heads struggled to remove tightly bonded sand, yielding poor cleaning performance. Consequently, it was decided to retrofit the cleaning equipment to better address the issue on Line B’s base plate. After further discussion, a revised design was adopted: a scraper blade was mounted above the base plate and secured with a torsion spring, allowing for a certain degree of flexibility. As the base plate moves along the conveyor, it passes beneath the scraper, which removes any loose sand particles, causing them to fall back onto the conveyor belt. In actual operation, it was found that, thanks to the scraper’s fixed mounting and the resulting substantial resistance, even tightly adhered sand on the base plate could be thoroughly removed—without requiring any external power—and the failure rate was significantly reduced. Moreover, the cost of retrofitting with a single scraper was far lower than other alternatives; compared with the original brush-head system, which required frequent replacement, this solution also resulted in substantial savings on materials. The new solution strikes an optimal balance between functionality and cost, delivering superior performance at a lower expense and thus representing an exceptionally cost-effective approach. Following implementation of the new design, the accumulation of sand on Line B’s base plate has improved markedly, enhancing the workshop environment while simultaneously reducing quality risks.
Due to inevitable sand loss or fragmentation of the sand mold shell during the molding process, the floor-mounted base plate of Line B in the foundry workshop often accumulates a large amount of waste sand. This situation not only leads to material waste and makes Line B dirty and disorganized, but also adversely affects production. The initial solution was to install two rotating sweeping heads driven by motors to clean the base plate; however, practical experience showed that this approach was largely ineffective, as the soft sweeping heads struggled to remove tightly bonded sand, resulting in poor cleaning performance. Consequently, it was decided to modify the cleaning equipment to better clean the base plate of Line B.
Following further discussion, it was decided to modify the design by installing a scraper above the bottom plate, which is secured by a torsion spring to provide a certain amount of clearance. During the conveyance of the bottom plate, sand that falls off the plate passes beneath the scraper, where it is scraped off and falls back onto the conveyor belt. In actual operation, it was found that, thanks to the scraper’s secure mounting and the resulting substantial resistance, even tightly adherent sand on the bottom plate is thoroughly removed—without requiring any additional power—and the failure rate has been significantly reduced. Moreover, the cost of retrofitting with a single scraper is far lower than that of other solutions; compared with the original sweeping head, which required regular replacement, this modification also results in substantial savings on material costs.
The new solution strikes a balance between functionality and cost, delivering superior results at a lower expense and thus offering exceptional value for money. Following its implementation, sand accumulation on the bottom plates of Line B has been significantly reduced, which has not only improved the workshop environment but also lowered quality risks.
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