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Hartley Compactability Controller with Bond Determinator (Continuous) 2552-C1

Automatic Control For Your Green Sand System

Controlling the consistency of your sand is essential in producing higher quality castings and increasing your overall profitability. By reducing human error and by providing data tracking, hundreds of foundries have increased process control and reliability. The Hartley reduces compactability swings, stabilizes moisture levels and reduces sand related defects.

Contact Us Foundry Data Sheet

The Simpson Hartley control system and compactability controller has been designed to precisely control green sand compactability, bond addition and water addition as well as provide full automation for an entire mixer/muller group. The compactability controller also measures and records green strength and moisture.

When combined with a capable continuous muller, the Simpson Hartley enables you to:

  • Accurately and automatically control prepared green sand to within ±3 compactability points from a desired set point (When a properly designed system and good sand handling practices are followed).
  • Interface with the sand system and/or molding line so that molding sand is produced only when desired and/or capable.
  • Automatically measure and control sand conditions.
  • Access sand data that can assist in determining the cause of your sand related scrap.

How it Works

  1. Measurements of the return sand temperature, moisture and feedrate are taken in the belt conveyor prior to dosing to the mixer. 
  2. On the discharge belt, the Hartley tester obtains a sample of the sand and conducts tests on the compactability, green strength (model 2552 only) and moisture. The results are compared to the desired targets and the process control logic is adjusted accordingly. 
  3. The data from each test (available fo display or can be exported to a data system) on all model testers includes: time of day, test number, return sand temperatures, return sand conductivity, target compactability, actual compactability, target water addition, actual water addition, maximum muller drive motor amperage, target bond weight, actual bond weight and compactability deviation. The model 2552 additionally provides green compression strength, available bond percentage and the available bond average (last five tests).
  4. Once the process inputs have been measured, the Hartley Controller calculates the required water addition to be added through a water injection system consisting of a positive displacement pulse flow meter and diaphragm valve to maintain a targeted compactability. The model 2552 additionally calculates the needed bond addition automatically. Weight based bond additions are added to the muller with the BFS Bond Addition System for the 2552-C1. 
  5. The control system is based on a high-performance, industrial programmable logic controller and has a touchscreen operator interface. The touchscreen provides display of, and the ability to adjust, all important parameters as well as diagnostic messages.

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“For the past three years, our Hartley has been trouble free and virtually maintenance free. The Hartley has met our challenge to control moisture and compactability swings head-on. Our payback was less than six months. Nor our sand conditions are great. We’ve noticed a substantial reduction in scrap and bad molds and have a very positive gain in productivity.” -President of a Grey and Ductile Iron Foundry

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