EP3041624B1

EP3041624B1 - Method of operating a metal foundry, system for performing the method, and metal foundry comprising the system

Info

Publication number: EP3041624B1
Application number: EP14767144.0A
Authority: EP
Inventors: Sten Haunstrup
Original assignee: Disa Industries AS
Current assignee: Disa Industries AS
Priority date: 2013-09-06
Filing date: 2014-09-08
Publication date: 2018-12-12
Anticipated expiration: 2034-09-08
Also published as: CN105517732B; ES2709197T3; JP3214316U; CN105517732A; JP2016529111A; WO2015033311A1; EP3041624A1

Description

The present invention concerns a method of operating a metal foundry, in paticular a green sand metal foundry, and a system for performing the method. The present invention further concerns a metal foundry comprising the system.
Technique for automatic operation of foudries are know. US5125448 discloses an automatic foundry plait in which information concerning the characteristics of each individual mould is sensed in the moulding machine and used in a downstream pouring unit for controlling the pouring of molten metal info the mould to which the information relates, The information is disclosed as relating to the type of mould, whether cores have been placed in the mould, whether the mould is suitably firm, and whether the mould is unsuitable for pouring due to other reasons. Using this information the pouring unit may be controlled to properly position the pouring nozzle in relation to the mould, of to not pour the specific mould to which the information relates. Information regarding whether a specific mould has been poured or not, as well as information regarding the weight of the specific mould, may then be provided by the pouring unit and used to control a water dosing unit for ensuring a proper amount of water in the moulding sand leaving an extraction station where the mould is broken up.
The methode described in US5125448 does not minimize, non measure, the environmental disturbances caused by the foundry operation, rather it focuses solely on ensuring a fault free operation based on information concerning the characteristics of each individual mould.
Further, WO89/09666 discloses a method and apparatus for evaporative casting. An evaporative pattern is positioned in a container. Moulding medium is compacted around it and the container is positioned under a pouring unit. As molten metal pours into the container and evaporates the pattern the gases generated by the pattern are evacuated using a vacuum pump. Pressure within the container is measured by pressure probes and used to control a modulating valve and a vacuum surge vessel connected to the pump. By controlling the pressure the flow rate of the molten metal is controlled. The methode described in WO89/09666 does not minimize, nor measure, the environmental disturbances caused by the foundry operation.
KR20120055925 discloses a local ventilation device and a multi-hood local ventilation method for fluctuating air pollutants.
DE102009031557 discloses a method of collecting heat from a strand casting process using a heat exchanger.
Metal foundries have in recent years become more focussed on environmental disturbances correlated with foundry operation due to the increased focus on such environmental disturbances and challenges of today's society and the need to provide a suitable environment for the workers of the metal foundries.
Some of the most relavant environmental disturbances related to the operation of a metal foudry include air pollution, CO₂ emissions, heat, noise, energy consumption, water consumption, and waste products such as spent sand, spent bentonite clay and discarded castings. Spent sand and bentonite clay cannot be recycled but must be discarded.
Further waste products include metal parts which are not part of the final casting but which form in feeders and risers, i.e, reservoirs in the mould, which are used to ensure a proper casting and solidification of the molten metal and are separated from the casting once it the casting has been separated from the mould.
Further raw materials, used for the operation of the metal foundry, which may be seen as environmental disturbances include consumption of metal, consumption of new sand and new bentonite clay, consumption of any addilives used to form the green sand and consumption of pressurized air or steam for running machines or providing heating.
Each of these environmental disturbances is relates to one or more unit operations in the metal foundry, As an example green sand foundry moulding, in which moulds or forms made from sand are used, broadly employ the unit operations of providing green sand, forming the green sand into a green sand mould, pouring molten metal into the green sand mould, allowing the molten metal to solidify, removing the green sand mould from the casting, and conditioning the green sand for reuse.
Air pollution, in the form of dust and fine particles, is typically related to the unit operations for handling and usig the green sand, i.e. providing, forming, and removing. Further, where the sand used comprises silica sub micron sized silica particles may be formed when the sand in the moulds are contacted by the molten metal during pouring of the molten metal into the moulds. Such particles may lead to silicosis in the workers. Metal foundries therefore need to spend a considerable effort on dust collection.
The dust caused by different unit operations in the metal foundry are of different substances and different compositions and may for example contain metal or metal oxides.
Air may also be polluted with combustion products, such as carbon monoxide, and/or volatile organic compounds (VOC).
Many operations in the metal foundry produce odours or fumes both in the interior environment, i.e. within the metal foundry, and in the exterior environment, i.e. the environment outside the metal foundry. These odours and fumes may be unpleasant or harmful to inhale.
Air in the environment outside the metal foundry may also be polluted by sulphur dioxide and nitrogen oxides from the fuel, such as coal, oil or gas, used to heat the furnaces used for melting the metal. If the metal that is to be molten comprises pieces of scrap metal or recycled metals, paints and coatings on the pieces of metal may result in the pollution of the air in the metal foundry for example dioxins. Also finishing treatment of casting such as grinding and welding may release toxic metal particles into the air.
Heat is mainly related to the unit operation of pouring the molten metal and allowing it to solidify. Heat is further released from the furnace used for melting the metal. Heat may cause dehydration, heat cramps, heat exhaustion and heat in workers in a foundry. Workers may also develop eye cataracts from infrared and ultraviolet radiation emitted from the molten metal. Splashes and sparks from the molten metal may also cause burns.
Noise may be related to any unit operation and may be of short duration, such as from impacts, or longer duration, such as the noise from a shake out machine. Most common noise sources are from moulding machines, shake out machines, and finishing operations such as shot blasting, are gouging, fettling and dressing of castings. The noises generally range between about 80 and 110dB(A), however some noise may be as high as 116dB(A). Another noise source is noise from using compressed air for cleaning moulds or for introducing mould material into the moulding machine.
Although personal hearing protectors are available it is common to not use them for noises of short duration, however the short duration noises add to the overall exposure, i.e. the overall environmental impact on noise.
Closely related to noise is vibration which may affect not only worker health but also the longevity, performance and maintenance requirements of the metal foundry machines, thereby ultimately affecting the efficiency of the metal foundry.
CO₂ emissions are typically related to the energy needed for melting the metal to be used in the foundry and the energy needed for running the machines, e.g. the sand moulding machine, the mould conveyor, the shakeout machine or the sand cooler, needed for performing the unit operations. Further energy is needed for providing ventillation of the metal foundry.
Consumption of water is related to removing the green sand from the castings, to conditioning the sand to provide a good mouldability of the sand when moulded in the sand moulding machine, for limiting dust formation at for example the shakeout machine, and for cooling.
Further, the consumption of water often results in waste water which needs to be taken care of properly. The waste water may for example contain metal dust or organic compounds. Waste water may also be caused by storages for metal scrap storing of slag on the ground outside the metal foundry due to rain water taking up pollutants from the scrap metal or slag and seeping into the ground.
All unit operations require energy to be performed.
Production waste is related to the unit operations of forming the sand, pouring the molten metal, removing the casting from the mould, and conditioning the sand for reuse. Production waste is further related to controlling the castings to detect defect castings which must be scrapped, i.e. which are easting scrap. Scrap can often be remelted, and that goes for slag too, however, in some cases slag has to be disposed of in a landfill.
Of these environmental disturbances, air pollution, heat, and noise primarily affect the worker environment whereas CO₂ emissions, energy consumption, water consumption and production waste primarily affect the environment surrounding the foundry. Energy consumption, water consumption and production waste further affects the cost of running metal foundry operations.
Further elaboration on the environmental impact of metal foundries is found in the report "Integrated Pollution Prevention and Control Refernce Document on Best Available Techniques in the Smitheries and Foundries Industry" July 2004, from the European IPCC Bureau.
To minimize the impact, associated with operating a metal foundry, on the environment CO₂ emissions, energy consumption, water consumption and production waste should preferably be as low as possible.
Further, in order to provide a suitable worker environment for the workers in the metal foundry, the air pollution and noise should be kept as low as possible and steps be taken to prevent the heat from causing too high a temperature in the foundry.
At the same time the metal foundry must be run so as to provide an efficient production of castings. For example the number of castings which are defect and must be scrapped must be as low as possible so that the number or useable, be proper, castings per unit of time and amount of environmental disturbance is a high as possible. This is because scrapped castings, which must be discarded or re-melted, represent production waste if discarded and require energy, i.e. heat, if re-melted. Further, even where the casting can be machined to a proper casting, for example if the casting is slightly defect due to mis-match of the mould halves resulting in a defects in the casting adjacent the parting lines of the mould, such machining or fettling requires both energy and labour and may expose workers or operator of the metal foundry to a difficult or unhealthy work environment. Thus keeping the number of useable, i.e. proper, castings per unit of time and amount of environmental disturbance as high as possible, minimizes at least those environmental disturbances related to scrapped castings and energy for re-melting.
It is therefore important to obtain a good interior environment, i.e. a low level of environmental disturbance on the workers in the metal foundry, and good exterior environment, i.e. a low level of environmental disturbance on the environment outside the metal foundry. Further the total level of environmental disturbances to the interior environment and the exterior environment should be as low as possible.
It is therefore an object of the present invention to provide a method of operating a metal foundry in which environmental disturbance are minimized while still providing an efficient production of castings.
It is a further object of the present invention to provide a system for performing the method of operating the metal foundry.
It is yet a further object of the present invention to provide a metal foundry comprising the system.
It is yet a further object to provide a method of reusing heat caussed by the operation of a metal foundry.
At least one of the above objects, or at least one of any of the further objects which will be evident from the below description, are according to a first aspect of the present invention achieved by the method according to claim 1.
By operating the metal foundry machine using at least one instruction obtained on the basis of the at least one measurement, the at least one instruction being configured to cause a decrease of the at least one environmental disturbance, it is ensured that the metal foundry is operated so as to lower the impact on the environment from the operation of the metal foundry.
By operating the metal foundry so as to lower the environmental impact of the operation of the metal foundry the operation of the metal foundry is also at least partly optimised.
In the context of the invention lowering the invironmental impact of the operation of the metal foundry refers to lowering the environmental disturbances caused by the at least one metal foundry machine, and accordingly by the operation of the metal foundry, in the vicinity of the metal foundry machine, in the metal foundry, and/or in the environment. Thus lowering the environmental impact of the operation of the metal foundry is beneficial to both the workers and operators of the metal foundry and the environment.
The metal foundry is preferably a metal foundry performing casting of metal using green sand moulds, however other types of mould material is possible.
The metal foundry machine may comprise a green sand storing and providing machine, a moulding machine such as a vertical green sand moulding machine, a flask moulding machine, a match plate moulding machine, a core shooter machine, a mould conveyor or moulding line, a pouring unit, a shakeout machine, a sand cooler, and a casting cleaning and treating machine etc. Generally the metal foundry machine may comprise any machine used in a metal foundry for the metal foundry operations.
Further the at least one metal foundry machine may comprise a ventilation device.
The steps of the method defined in claim 1 should be performed in the order of i, ii, iii.
The at least one measurement may be quantitative such as a number or value, or qualitative such as a Boolean value. The at least one measurement may be obtained in the metal foundry machine, in the vicinity of the metal foundry machine, e.g. besides, above etc., within the metal foundry, i.e. within the building housing the metal foundry machine, or outside the metal foundry.
The at least one measurement may be a measurement of the amounte, intensity, occurrence, extent, or concentration ect of the environmental disturbance. One example is the measurement of usage of power for a certain metal foundry machine.
The measurement may be a direct measurement of the environmental disturbance produced by the metal foundry machine, or an indirect measurement of the environmental disturbance, that is a measurement of an environmental parameter influenced by the environmental disturbance.
As an example air pollution is typically due to dust formed, during handling of the green sand or other mould material. Dust may be measured by a direct measurement, e.g. by measuring the amount of dust particles caught in a filter or on a charged membrane during a specified time. Dust may also be measured by indirect measurement by measuring much light emitted from a light source is received by a photo detector.
Where multiple measurements of the at least one environment disturbance are measured, such as multiple measurements of air pollution from different positions in the metal foundry, these multiple measuremets may be combined with measurements from other sensors indicating flow of air in the metal foundry into a 3D-model for extrapolating the air pollution at any point in the metal foundry.
Thus the measurement may be obtained directly by a sensor, thus resulting in a measurement of the environmental disturbance in the position of the sensor. Alternatively the measurement may be obtained at a desired position, in which there is no sensor, by using sensor data from a number of sensors at different positions and extrapolating the measurement in for the desired position from the sensor data.
The at least one instruction is configured to cause a decrease of the at least one environmental disturbance. In other words the at least one instruction is suitable for causing a decrease of the at least one environmental disturbance. This means that the at least one instruction is one which, when used to operate the at least one metal foundry machine, is determined empirically or analytically to cause a decrease of the at least one environment disturbance. Thus there is an empirical or analytical or logical relationship between the at least one instruction, the at least one metal foundry machine, and the at least one environmental disturbance. The relationship between the at least one environmental disturbance and the at least one instruction causing a decrease of the environmental disturbance may be determined empirically, by operating the at least one metal foundry machine under different conditions, using different instruction, and obtaining at least one measurement of the at least one environmental disturbance for each of the different conditions. The relationship may also be determined analytically or logically by considering how and why the at least one environmental disturbances is produced by the metal foundry machine. As one example it may be readily empirically determined that spraying water onto dust generating unit operations, such as the shakeout machine, reduces dust, thus increasing the amount of water sprayed will result in decreasing the amount of dust formed. As another example it may readily be analytically or logically determined that decreasing the speed of a moulding conveyor decreases the noise caused by running the moulding conveyor.
In the context of the present invention the term obtaining is to be understood as aslo, comprising the terms determining and calculating.
Using the at least one instruction may comprise controlling the at least one metal foundry machine directly, i.e. at least one metal foundry machine's control interface or control computer, or indirectly by controlling an external source, such as a source of water power, pressurized air etc., to which the at least one metal foundry machine is connected for receiving said water, power, pressurized air etc.
The at least one instruction may be used operat the at least one metal foundry machine by being used to control a supply of a medium to the machine, e.g. control a valve for delivering water to the metal foundry machine, control the speed of the motor of the least one metal foundry machine.
Where the at least one metal foundry machine produces more than one environmental disturbances these more than one environmental disturbances are often of different types. It is however contemplated within the context of the present invention that the more than one environmental disturbances produced by the at least one metal foundry machine may be of the same type, however obtained at a different location in relation to the at least one metal foundry machine. The type of environmental disturbance is determined by the physical nature of the environmental disturbance. For example one type of environmental disturbance may be dust, i.e. particles, while another type of environmental disturbance may be noise, i.e. sound waves. Other types include heat, i.e. energy and consumption of a resource.
Where more than one instructions are obtained based on more than one environmental disturbances for operating the at least one metal foundry machine, one of the more than one instructions may, while being configured to cause a decrease of one of the more than one environmental disturbances, at the same time cause an increase in another of the more than one environmental disturbance. In this case the method as defined in claim 1 may further comprise the step of obtaining an order of priority of the more than one environmental disturbances, and based on this order of priority perform the further step of modifying one of the more than one instructions, such that the one of the more than one instructions that causes the descrease of the one of the more than one environmental disturbances having the lower priority is rendered ineffective before using it to operate the at least one metal foundry machine, or vice versa.
Alternatively the method as defined in claim 1 may additionally comprise the step of determining whether or not the more than one environmental disturbances and the more than one instructions configured to cause a desrease of these environmental disturbances, are such as to risk running counter to each other as described above, and further the step of obtaining an order of priority of the more than one environmental disturbances.
Generally a metal foundry comprises a first plurality of metal foundry machines. Accordingly claim 2 defines a preferred embodiment of the method according to the first asped of the present invention. The embodimentaccording to claim 2 is advantageous as in this embodiment the method according to claims 1, i.e. the steps i-iii is are performed for each of the first plurality of metal foundry machines, thus resulting in a large overall decrease of the at least one environmental disturbances for a large lowering of the environmental impact of the operation of the metal foundry.
Each of the first plurality of metal foundry machines are preferably different from each other.
Generally a metal foundry comprises a first plurality of metal foundry machines producing a second plurality of second environmental disturbances. Accordingly claim 3 defines a preferred embodiment of the method according to the first aspect of the present invention. The embodiment according to claim 3 is advantageous as in this embodiment the method according to claims 1, i.e. the steps i-iii is are performed for each of the first plurality of metal foundry machines and for each of the second plurality of environmental disturbances, thus resulting in a large overall decrease of the second plurality of environmental disturbances for a large lowering of the environmental impact of the operation of the metal foundry.
The second plurality is preferably greater than the first plurality, in other words at least one of the first plurality of metal foundry machines preferably produce two or more environmental disturbances.
The third plurality is preferably greater than the first plurality but may also be less than the first plurality, In the latter case the environmental disturbances produced by more than one of the first plurality of metal foundry machines may be measured collectively in a single measurement for these metal foundry machines.
The fourth plurality may be equal to or greater than the first plurality, in other words each of the first plurality of metal foundry machines may be operated using one of the fourth plurality of instructions.
Claim 4 different advantageous embodiments of the method, according to the first aspect of the present invention as regards the step of obtaining the at least one instruction. Using at least one thershold value is an easy method of lowering the environmental impact of the operation of the metal foundry as a threshold value is easily set.
Depending on the environment disturbance measured, the at least thershod value may be an upper or lower thershold value. The at least one thershold value should be selected so as to define the level where the environmental distribance results in a environment that is harmful to the workers or the operators of the metal foundry, or where the environmental disturbance damages the environment or results in defective castings.
The at least one thershold value may be set manually by a worker or an operator of the metal foundry and/or the metal foundry machine. The at least one thershold value may also be set automatically, for example by being calculated according to some algotithm. For example the at least one thershold value could be set to the product of a factor and the mean value of the at least one measurements of the at least one environmental disturbance during the previous month, week or day, thus the at least one thershold could be automatically updated to for example 110% of the mean value of the at least measurements of the at least one environmental disturbance during the previous month. The at least one threshold value may alternatively be set such that an estimation of the integral of the at least one measurements of the environmental disturbance over a certain future time period, results in a total environmental disturbance below a certain amount. The thershold value for the measurement of a first environmental disturbance may additionally be influenced by the thershold value of a second environmental disturbance either where there is a synergic effect of the first and second environmental disturbance, for example heat and noise having a synergistic effect on worker environment, or where the first or second environmental disturbance has a higher priority i.e is more important to keep within the acceptable range defined by the thershold value realated to the measurement of the first environmental disturbance, than it is so keep within the acceptable range defined by the thershold value related to the measurement of the second environmental disturbance.
The at least one thershold value may further be set according to official guidelines or laws. For example, as regards air pollution of lead (Pb) the mandated threshold value in air is 50 µg lead/m³. In the example with lead further, higher thresholds are set by official guide lines or laws, these higher thersholds being 50-75 µg lead/m³ and requiring the use of personal safety aquipment, and checking the health of the workers respectively. Managese (Mn), which is an additive used in metal foundries for casting steel and special steels, has an official thershold level of 0,1 mg/m³ air for manganese in breathable form and a thershold level of 0,2mg/m³ air for manganese as smoke, dust or powder. Manganese is very toxic and cause serious and irreparable damage to the brain and the nervous system.
The at least one comparison result may be a value indicating how much the at least one measurement differs from the at least one threshold value, or it may be Boolean value indicating whether or not the at least one measurement is within the range defined by the at least one threshold value and a measurement when the metal foundry is not operated. Where the at least one measurement is a direct measurement the at least one threshold value is typically an upper threshold value whereas when the at least one measurement is an indirect measurement the at least one threshold value is typically a lower threshold value.
Looking up the at least one instruction in a look up table is fast while using a function operating on the at least one comparison result or the at least one measurement provides more different instructions for a more exact and minute operation of the at least one metal foundry machine.
The look-up table may comprise measurements values where each measurement value is correlated to a corresponding instruction. The instruction corresponding to a certain measurement value may have been determined empirically, by testing different instructions for a certain measurement value of the environmental disturbance and including in the look up table the instruction lowering the environmental disturbance the most. The instruction correlated to a certain measurement value may alternatively be determined analytically by considering how different instructions would affect the environmental disturbance.
Additionally the instruction corresponding to a certain measurement value may be set by past experience, i.e. by considering whether a certain instruction, such as for example increasing the flow of water to the shake out machine, was executed in the past or previous hour or day of operation of the metal foundry for the measurement that has been obtained. Thus, where an operator or worker of the metal foundry provides an instruction for operating the at least one metal foundry machine, the instruction corresponding to the measurement value the at the time the operator or worker provided the instruction, this instruction corresponding to the measurement value in the look up table may be set to the instruction provided by the operator or worker.
Further, instructions to the look up table for a certain measurement value may be set to the instructions prevailing at the cessation of operation of the metal foundry, for that certain measurement value, such that next time the operation of the metal foundry commences again it starts with the instructions prevailing at the cessation of operation of the metal foundry.
Obtaining the instruction from a worker or operator of the metal foundry provides for handing exceptional environmental disturbances outside the allowed input values for the look up table and the function. The instruction obtained by the operator or worker, together with the measurement value which prompted the instruction from the worker or operator, may then be stored in the look up table for future use.
The look up table may comprises more than one threshold for each measurement value. Thus, at a first threshold corresponding to a comparison result which shows a small deviation of the measurement value a first instruction may be obtained. This first instruction may result in a small change of operation of the metal foundry. At a second threshold, corresponding to a comparison result which shows a large deviation of the measurement value a second instruction obtained resulting in large change in operation of the metal foundry machine. The second instruction may for example be obtained from the operator or worker of the metal foundry.
In some embodiments of the method according to the first aspect of the present invention the method further comprises the steps of:

Obtaining information about the operation of the metal foundry, and
using the information when obtaining the at least one instruction.

The information may for example comprise the intended production rate of the metal foundry, the type of mould used in the metal foundry, the number of moulds on the mould conveyor, the weight of each mould, whether or not the moulding machine and the mould conveyor are running, etc.
This information may be used for obtaining instructions which proactively operate the metal foundry machines. As an example the measurement value for air pollution / dust at the shake out machine may reflect a low value of air pollution during a pause in operation. To lower the environmental impact the method attempts to further lower the water consumption. As the operation is paused no moulds are delivered to the shake out machine, there-fore no dust is created by the shake out machine which allows the water consumption to eventtually be off completely. Using the information, in this case information that the operation has now commenced again for example by obtaining on moulds being produced by the moulding machine, supply of wateto the shake out machine may be activated proactively so that there is already water being supplied to the shake out machine when the first mould is delivered thereto after operations has commenced again. This may avoid suddenly releasing dust from the first mould and a corresponding peak in air pollution before the air pollution has been delected and the supply of water to the shake out machine resumed.
The information may be obtained from a controlling computer and/or from an operations sensor associated with the respective metal foundry machines.
The information may be used as an additional input to the at least one measurement in order to modulate the obtained instruction, or may be used to obtain a different instruction than the one obtained solely on the basis of the measurement.
The information may also be used to set the instructions in the look up table or for setting thresholds. This may result in a more proactive operation of the metal foundry.
This information may for example comprise information, such as the current speed of a metal foundry machine, which is derivable from measurement or currently executed instructions for other metal foundry machines. Thus this information may for example be obtained from the moulding machine, by analysing the instruction currently used to operate the moulding machine. This information may for example comprise the number of moulds formed per hour. This information may then be used to proactively set in the look up table an instruction for the shake out machine, this instruction being known from past experience to be suitable for keeping air pollution within the thresholds.
Thus the look up table may comprise more than one input parameter for each instruction. To exemplify the look up table may comprise a first input for the measurement value of the environmental disturbance, in this case dust/air polluution caused by the shake out machine. The look up table may further comprise a second input for the number of moulds per hour that is being made, the number of moulds per hour being an example of the information about the operation of the metal foundry. These first and second inputs may be prioritized for example such that during the first hour of operation the shake out machine may be operated using an instruction that is to the present number of moulds per hour. After the first hour however the shake out machine may be operated using an instruction that is correlated to the measurement value of the air pollution at the shake out machine. In this way a better and more robust operation of metal foundry machines is achieved.
Information about the operation of the metal foundry may be used to obtain instructions of metal foundry machines such as compressors for air. In this case the information may comprise the total requirement of pressurized air for the metal foundry machines in the metal foundry. The information may further comprise pressure measurements for the reservoir of pressurized air of the compressor.
As regards air pollution information of when production is to be started may be used to obtain an instruction for starting a ventilation or air filter system prior to actual commencement of operation of the metal foundry.
Further information about whether or not a moulding machine is running may be used to obtain an instruction for stopping a metal foundry machine such as a shake out machine or mould conveyor if no moulds are produced by the moulding machine, thereby saving money and resources. In this case the information about the operation of the metal foundry may be obtained from the controlling computer directly or by operations sensors connected to the moulding machine.
Likewise information the operation of the foundry may be used to control lighting of the metal foundry for avoiding lighting up the metal foundry if there is no operation of the metal foundry.
Where long time production goals are known and comprised by the information, this information may be used to obtain instructions to the at least one metal foundry machine for causing the at least one metal foundry machine to operate at the lowest speed still allowing the required production goal to be achieved.
If the information, or at least one measurement, comprises an air temperature this air temperature may be used to obtain for pre-heating an air extraction duct so that hot air from the metal foundry does not condense in the extraction duct causing sand and dust to aggregate in the extraction duct. Such aggregations are difficult to remove, thus the prevention of the formation of such aggregates is desired.
Further, information about the operation of the metal foundry may be used to reduce noise by operating the moulding machine and mould conveyor at a lower speed.
Information about the operation of metal foundry may also be collected from operation sensors such as vibration sensors which may be used to to warn of imminent failure, as diagnosed by vibrations, of the at least one metal foundry machine. This increases the longevity of the metal foundry machine. Also, oil quality sensors may be used to mesure and analyze lubricating or hydraulic oil in order to operate the metal foundry machines so as to prevent failure thereof.
Other operation sensors include image sensors for obtaining information on mould quality, Hyperspectral imaging using hyperspectral sensors may be used to mesure air pollution caused by dust and/or chemicals.
The embodiment according to claim 5 is adventageous as in this embodiment the operation of the metal foundry is optimized so that the total amount of environmental disturbances is minimized. The first sum and the second sum may be formed by multiplying each of the respective mesurements of the environmental disturbances with a constant for obtaining a common unit for the value of the sums. This unit may for example be cost or energy. The common unit may be dimensionless by dividing each measurement with a base measurement. For example a noise level in dB may be divided by a base measurement of 100 dB. Similarly a power measurement in watt may be divided by a base measurement of 1000 Watt. The value of the base measurement for each measurement may be used to weight the impact that each environment disturbance should have on the sum of environmental disturbance. Thus if the value of the base measurement is small the corresponding environmental disturbance will contribute more to the sum of environmental disturbances and vice versa.
To make the sum of environment disturbances a cost the value of each base measurement should be set to reflect the cost associated with operating the metal foundry at the amount of corresponding environmental disturbance that is measured. For example, as regards power, the value of the base measurement is the cost of each watt hour of power that is consumed. Likewise the value of the base measurement for water usage is the cost per m³ consumed water. Waste water that must be released to a municipal waste water treatement plant similary entails a cost per m³. Filters used in air filtration devices, for filtering polluted air also entails a cost per m³ of air filtered and the amount of pollution in the air.
Instead of having a single constant base measurement for each enviromental disturbance when computing the first sum, a base function may be set for each environmental disturbance. The base function takes as input the measurement value of the corresponding environmental disturbance and returns a dimensionless number or a cost. In fact, a base measurement as described above represents a simple base functions. A more complicated base function may comprise a quadratic, polynomial, linear, exponential or other relationship between the measurement and the cost. The base function may further be discontinuous such as for example in the case of a base function for noise in which noise levels below a first threshold entails no costs, noise levels above the first threshold and below a second threshold result in a moderate cost based on the cost of providing workers with hearing protection, and noise above the second threshold entails a high cost based on needing to discontinue operation of the metal foundry, with concomitant loss of earnings, due to violating laws on worker environment.
A further example of a discontinuous base fuction is the cost for electrical power where the cost per watt may be different for different times of the day and night. Such a differentiated cost of electrical ppower will influence the operation of the metal foundry. One example related to minimizing air pollution comprises increasing power to fans in a ventilation unit during the night when electrical power is cheap, thereby allowing decreasing the water supply to the shake out machine and thereby reducing the cost of water. At daytime, when electrical power is expensive, the electrical power to the fans is decreased and the supply of water to the shake out machine is increased, In both cases, night operation and day operation,: the air pollution is minimized while taking advantage of the lower cost of electrical power at night.
Step vi may further comprise obtaining at least one previous instruction, the previous instruction being associated with the status of the at least one metal foundry machine at which the at least one measurements are obtained, storing the at least one previous instuction, and provided the estimation of the second sum is larger than the first sum, causing the at least one instruction obtained in step ii to be identical to the at least one previous instruction before performing step iii.
This ensures that if the estimation of the second sum is larger than the first sum the at least one previous instruction is used to operate the at least one metal foundry machine.
The estimation may be obtained by modelling the at least one metal foundry machine using an empirical or analytical or logical correlation between the measurement of the at least one environmental disturbance and that at least one instruction.
An empirical correlation between the measurement of the at least one environmental disturbance and the at least one instruction may for example be determined empirically by running the metal foundry machines using differed instructions, in the case of a mould conveyor at different speeds, and for each instruction measuring and storing the values of the environmental disturbances. In the case of a mould conveyor the mould conveyor would be run at different speeds and the noise produced at each speed would be measured and stored. The measurements may be used to construct a look up table, or alternatively may serve as data for making a linear or other regression suitable for use in a function taking as input an instruction and providing as output the amount of environmental disturbance produced when operating a metal foundry machine using the instruction.
A case of an analytical or logical correlation between the measurement of the at least one environmental disturbance and the at least one instruction may for example be found for the water consumption in the shake out machine as in this case the instruction to increase the water supply with 50% logically results in an increase of water consumption by 50%.
Thus, once the at least one instruction has been obtained this at least one instruction is used in the above mentioned look up table, regression or function to obtain a corresponding measurement of the at least one environmental disturbance. The second sum may then be calculated by obtaining the cost or amount of the environmental disturbance using the base measurement or base function mentioned above.
Claim 6 defines different environmental disturbances. Air pollution may be air pollution due to dust, sand fines, mineral fines, chemical vapours, metal droplets, metal vapours etc. Heat may comprise hot air, hot steam, and hot fluids. Noise may comprise sound, vibrations etc, CO₂ emissions may comprise CO₂ emissions occurring directly from the metal foundry machine, and/or CO₂ emissions occurring indirectly through the power usage of the metal foundry machine. Energy consumption comprises the energy consumed by the metal foundry machine. Water consumption comprises the water consumed by the metal foundry machine. Production waste comprises waste in the form of green sand which cannot be re-used, defective castings which must be discarded or molten down, surplus metal from the pouring of molten metal, etc. Further environmental disturbances include drafts and air jets, release of pressured air etc from the metal foundry machine.
Claim 7 defines different instruction. Controlling the speed of the metal foundry machine may comprise lowering the speed which, dependent on the metal foundry machine, reduces noise, air pollution, energy consumption, water consumption, and/or CO₂ emissions. Controlling the supply of water to the metal foundry machine may comprise increasing the water flow causing a reduction in formation of dust, thus reducing air pollution. Controlling lubrication of the metal foundry machine may comprise adding lubrication to the metal foundry machine causing a reduction in power consumption. Controlling means for counteracting the environmental disturbance may comprise controlling fans, fresh air inlets, filters, air cleaners etc, to reduce air pollution, controlling an air conditioner to reduce heat, etc.
Claim 8 defines a preferred embodiment of method according to present invention. The heat exchanger not only reduces heat by absorbing it, it also makes the heat available for reusing for heating other parts of the metal foundry or for generating electricity.
Preferably the heat exchanger is mounted over a metal foundry machine such as a moulding conveyor, melting furnace, pouring furnace or moulding line to absorb the heat from the molten metal in the moulds.
Further metal foundry machine above or in relation to which the heat exchanger may be placed for absorbing heat includes heated and unheated pouring units such as casting ladles.
Thus the present invention also provides that energy may be reused from a moulding conveyor, melting furnace, pouring furnace or moulding line by absorbing heat from the molten metal in the moulds and using this heat for heating or electricity generation, via a suitable turbine, while the absorption of the heat also provides a better environment, i.e. less hot, for the workers or operators of the metal foundry.
Preferably the energy absorbed by the heat exchanger is used to power the metal foundry machines and/or the ventilation machines which provide ventilation for the metal foundry.
In a preferred embodiment of the method according to the first aspect of the present invention the measurement and/or the comparison result may be displayed on the metal foundry machine, on a printout or computer screen, on a central printer or computer screen, or remotely on a computer. PDA, or Smartphone. This is advantageous as it allows the worker or operator of the metal foundry to be informed of the environment and the measurements of the environmental disturbances.
At least one of the above objects, or at least one of any of the further objects which will be evident from the below description, are according to a second aspect of the present invention achieved by the system according to claim 9.
The system according to the second aspect of the present invention performs the method according to the first aspect of the present invention.
Preferably the at least one sensor is placed in the vicinity of the at least one metal foundry machine; however it may also be placed within the a least one metal foundry machine, associated with a resource required by the a least one metal foundry machine, in the metal foundry, or outside the metal foundry.
The at least one sensor may be an air quality sensor such as a CO₂ sensor, and O₂ sensor, an O₃ sensor, a dust content sensor, a smoke sensor, a gas sensor, a relativite humidity sensor, an airflow sensor.
The at least one sensor may further comprise a heat sensor such as a temperature sensor or a radiant heat (IR) sensor.
The at feast one sensor may further comprise a flow sensor such as a water flow or usage sensor, a green sand flow or usage sensor, etc.
The at least one sensor may further comprise a power sensor (measuring electrical power used by a metal foundry machine).
The at least one sensor may comprise a microphone or sound meter to measure noise. Further the sensor may be a vibration sensor to measure vibrations.
The least one sensor may be a pressure transducer or strain gauge for measuring pressures and forces present between parts of the metal foundrymachines, and/or between moulds and the metal foundry machines.
The at least one sensor may be a vision system for obtaining and processing images of metal foundry machines, details of metal foundry machines, moulds, casting, sand etc. The at least one sensor may further comprise an electric field sensor or a magnetic field sensor.
The at least one sensor may be a scale for weighing production scarp or green sand waste. The at least one sensor may additionally be comprise a PDA, computer or Smartphone used by a worker to manually provide a measurement, for example the subjective air quality experienced by the workers or operators or the amount of fettling, i.e. manual treatment of the castings such as cutting, sandblasting, and polishing.
The at least one sensor may be connected to the central computer either wirelessly or by wire.
The at least one sensor is configured to obtain at least one measuement of the at least one environmental disturbance. This means that theat least one sensor is suitable for obtaining at least one measurement of the at least one environmental disturbance.
The controlling computer is configured to obtain the at least one measurement and the at least one instruction. This means that the controlling computer is suitable for obtaining the at least one measurement and the at least one instruction.
The controlling computer may be a server or personal computer running a program causing the computer to be configured for the tasks defined in claim 9. The central computer may host a server or site for displaying and making avalaible the measurement and/or comparison result to local or remote workers or operators of the metal foundry. The controlling computer may comprise a screen for displaying the measurement and/or the comparison result to the workers or operators of the metal foundry.
The controlling computer is further preferably configured to, or suitable for, communicating the at least one instruction to the controlling device.
The at least one controlling device may comprise any device for operating the at least one metal foundry machine using the at least one instruction. Examples include an electronically or pneumatically actuated valve, an electronic speed controller for controlling the speed of a metal foundry machine, an electronically controlled lubrication pump, an electronic relay for activating an air-condition or air cleaning device, etc.
The controlling computer may be configured for obtaining the at least one instruction by being configured to perform the method according to claim 4 as defined in claim 4 and described in relation to claim 4 above.
In some embodiment the controlling computer is further configured for obtaining information about the operation of the metal foundry, and using the information when obtaining the at least one instruction.
The controlling computer may for example be configured to store or access the intended production rate of the metal foundry, the type of mould used in the metal foundry, the number of moulds on the mould conveyor, the weight of each mould, whether or not the moulding machine and the mould conveyor are running, etc.
In some cases the system according to the second aspect of the present invention may comprise at least one operations sensor configured for obtaining at least part of the information. The operations sensor may for example comprise a motion detector, for detecting motion of the mould conveyor, a weight sensor for determining the weight of a mould, an image sensor for detecting workers in the metal foundry. The operations sensor may be associated with a metal foundry machine or alternatively the controlling computer may be configured for obtaining the information directly from a metal foundry machine.
The controlling computer may be configured to use the information for as an additional input to the at least one measurement in order to mediate the obtained instruction. In some cases the controlling computer may be configured to prevent execution of the obtained instruction until the information shows that a criterium, for example that the production is running, is fulfilled.
Further operations sensors include vibration sensor, oil quality sensor, image sensors, humidity sensors and hyperspectral sensors.
A preferred embodiment of the system according to the present invention is defined in claim 10. Generally metal foundries comprises a first plurality of metal foundry machines producing a second plurality of environmental disturbances, thus the embodiments according to claim 10 is advantageous as it decreases the total amout of environmental disturbances.
The fifth plurality may be greater than the second plurality where more than one sensors are configured obtaining a measurement of the same environmental disturbance.
The sixth plurality may be less than the fourth plurality where at least one of the controlling device can handle more than one instruction.
In correspondence to the method according to claim 1 the controlling computer may be configured to obtain an order of priority for the environmental disturbances for prioritizing the instructions if there are more than one environmental disturbances and more than one instructions.
The preferred embodiment the system according to the present invention defined in claim 11 minimizes the environmental impact
The summing module, the modelling module, and the control module may be implemented in hardware or software. The controlling computer is preferably configured to perform the method according to claim 5 as defined in claim 5 and described in relation to claim 5 above.
The metal foundry as defined in claim 12 has a lower environmental impact.
The metal foundry as defined in claim 13 has an even lower environmental impact.
The system according to the second aspect of the present invention is especially suited for a green sand metal foundry as defined in claim 14.
The preferred embodiment of the metal foundry as defined in claim 15 provides an even lower environmental impact by reusing heat from the metal foundry machines.
The means for converting the heat absorbed by the heat exchanger may include a thermo-couple, a steam turbine, a heat pump etc. The energy may be heat energy or electric energy, etc.
The heat exchanger as defined in claim 15 may be used in a foundry as defined in claim 15 without the system according to the second aspect of the present invention.
Thus a metal foundry comprising any of a moulding conveyor, a pouring unit, a melting furnace, a pouring furnace or a moulding line, may comprise a heat exchanger placed so as to absorb heat from any of said moulding conveyor, pouring unit, melting furnace, pouring furnace or moulding line, and the metal foundry may further comprise means for converting the heat absorbed by the heat exchanger to energy for operating the metal foundry and the metal foundry machines in the metal foundry.
The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments, and in which:

Fig. 1 shows a metal foundry comprising a system according to the second aspect of the present invention for operating the metal foundry in accordance with the method according to the first aspect of the present invention;
Fig. 2 shows the system according to the second aspect of the present invention and its connection to an exemplary metal foundry machine, and
Fig. 3 shows flow diagrams of embodiments of the method according to the first aspect of the present invention.

In the below description, a superscript roman numeral added to a reference number indicales that the element referred to has same or similar function as the element designated the non-superscripted reference number, however, differing in structure.
When further embodiments of the invention are shown in the figures, the elements which are new, in relation to earlier shown embodiments, have new reference numbers, while elements previously shown are referenced as stated above. Elements which are identical in the different embodiments have been given the same reference numerals and no further explanations of these elements will be given.
Fig. 1 shows a metal foundry, in its entirety designated the reference numeral 2. The metal foundry 2 comprises a plurality of metal foundry machines as will now be described. A first metal foundry machine is a green sand storing and providing machine 10 which comprises a silo 12 for holding green sand, an elevator 14 for receiving reused sand and transporting it to the silo 12, a screen 16 for conditioning and sorting sand, a sand mixer 18 for mixing sand, and a sand measurement device 20 for providing a controlled flow of green sand to a convey or 22.
Green sand is delivered from the green sand storing and providing machine 10 via conveyor 22 to a second metal foundry machine which is a vertical green sand moulding machine 30. Vertical green sand moulding machine 30 receives the green sand with a hopper or sand supply unit 32 and form the green sands into mould by pressing a shot of green sand between a pair of pattern plates (not shown). Where needed for forming void in the casting a core (not shown) may be attached to one or both sides of the green sand mould 34 exiting from the vertical green sand moulding machine 30. The core is produced from green sand or other materials in a third metal foundry machine which is a core shooter machine 40.
After the green sand mould 34 has exited the vertical green sand moulding machine 30 it is passed to a growing line of sand moulds carried by a fourth metal foundry machine which is a mould conveyor 50. Two green sand moulds 34, when placed together, form a moulding cavity between them for receiving molten metal.
Molten metal is then poured by a pouring unit such as a casting ladle (not shown) into the mould cavities formed by the array of green sand moulds 34 present on the mould conveyor 50.
During the pouring ashes from burnt off components of the green sand mould 34 may escape into the air and thus these ashes represent air pollution produced when running the mould conveyor 50 and/or the pouring unit.
A heat exchanger 52 is placed above the conveyor 50 for reveiving some of the heat emitted by the molten metal in the green sand moulds 34. The heat exchanger 52 may include an elongated shroud for collecting hot air rising from the green sand moulds 34 on the conveyor 50 and tubing placed within the shroud, through which tubing a heat exchanger fluid is passed so as to be heated by the hot air. The heated fluid may be used to drive a turbine for converting the heat of the hot air to electrical energy using a geneerator connected to the turbine. Alternatively the heated fluid may be used to heat other parts of the metal foundry or for providing steam for the metal foundry machines. The electrical energy can also be used to power the metal foundry machines.
After the molten metal has solidified the green sand mould 34 is deposited into a fifth metal foundry machine which is a shake out machine 60. The shake out machine 60 causes the green sand moulds 34 to separate and break up so that the green sand moulds 34 are re-moved from the castings. Water is added through spray heads, one of which is designated the reference numeral 62.
The shake out machine 60 then passes the castings and green sand moulds 32 to a sixth metal foundry machine which is a sand cooler 70 comprising a drum 72 through which the castings and green sand moulds 34 are led. Water is added to the drum 72 to further remove the green sand from the castings and to further break down and cool the green sand. The water further humidifies the sand and reduces air pollution in the form of sand and dust produced when running the sand cooler 70. The sand cooler 70 also cools the castings. The sand cooler 70 further includes a disintegrator for further breaking down the sand into individual grains before the green sand is passed on to a seventh metal foundry machine which is a third conveyor 80 which conveys the sand back to the green sand storing and providing machine 10 for reuse. The third conveyor 80 further comprises a magnetic separator 82 for removing any iron or steel particles present in the green sand.
After passing through the sand cooler 70 the castings are passed onto a eighth metal foundry machine which is a casting cleaning and treating machine 90 in which the castings are further cleaned, removing any sand residue, cooled, and collected for further processing.
As regards environmental disturbances the green sand storing and providing machine 10, when used in the operation of the metal foundry 2, produces dust and noise, thus air pollution and noise are environmental disturbances for this machine. Further environmental disturbances related to the green sand storing and providing machine 10 are water usage and power usage.
Vertical green sand moulding maching 30 and core shooter machine 40, when used in the operation of the metal foundry 2, also produce dust and noise, thus air pollution and noise are environmental disturbances for these machines. Further these machine require power, therefore power usage is also an environmental disturbance for these machines.
Mould conveyor 50, when used in the operation of the metal foundry 2, requires power and creates noise, thus power usage and noise are environmental disturbances for this machine. Further the heat of the molten metal in the green sand moulds 34 causes large amount of heat to be emitted by the green moulds 34 on the mould conveyor 50, thus heat is an environmental disturbance related to this machine.
Shake out machine 60 generates, when used in the operation of the metal foundry 2, both dust and noise, thus air pollution and noise are environmental disturbances for this machine. Further this machine requires power to and to limit dust making power usage and water consumption environmental disturbances for this machine.
Sand cooler 70 generates, when used in the operation of the metal foundry 2, both dust and noise thus air pollution and noise are environmental disturbances for this machine. To cool the green sand and the eastings, and to limit dust formation, water is used by the sand cooler 70, thus water usage is an environmental parameter of this machine. Also power is used by this machine, thus power usage is also an environmental disturbance of this machine.
The third conveyor 80 requires power to run and generates both dust and noise, thus power usage, air pollution and noise are environmental disturbances for this machine.
Casting cleaning and treating machine 90 requires power to run and generates noise, thus power usage and noise are environmental disturbances for this machine.
Metal foundry 10 further comprises a system, in its entirety designated the reference numeral 100 for operating the metal foundry. System 100 comprises a controlling computer 110, a plurality of environmental disturbance sensors (not shown in fig 1), and a plurality of operating devices or devices (not shown in fig 1). The environmental disturbance sensors are distributed throughout the metal foundry 10, and are preferably placed in the vicinity of the metal foundry machines.
The controlling computer 110 includes a display112, the use of which will be described in relation to fig. 2 and 3. The controlling computer 110 may further communicate via network 140 with a Smartphone 150 as will be described further below.
The vertical green sand moulding machine 30 shown in fig. 1 may be substitued by a horizontal flaskless matchplate machine.
The core shooter machine 40 may be any of a Cold-Box, Hot-Box,Croning, SO₂ or inorganic -core shooter machine.
Fig. 2 shows the system 100 in relation an exemplary metal foundry machine, in this case shake out machine 60. An environmental disturbance sensor which is an air quality sensor 120 is placed in the vicinity of the shake out machine 60 and connected to the controlling computer 110 via wire or wirelessly. The air quality sensor 120 is placed so as to measure the air quality, and accordingly any air pollution, caused by the shake out machine 60.
The system 100 further comprises a controlling device, connected by wire or wirelessly to the controlling computer 110, for controlling the operation of the shake out machine 80. In fig. 2 this controlling device is embodied by a controllable valve 130 governing the supply of water to the shake out machine 60.
Further environmental disturbance sensors comprised by the system 100 include noise sensor 120^I heat sensor 120^II, energy consumption sensor 120^III, water consumption sensor 120^IV, and production waste sensor 120^V.
The controlling computer 110 may the measurement and/or the comparison result via the network 140 to the Smartphone 150 as described below.
Although in fig. 2 the respective sensors, including inter alia air quality sensor 120, are placed in the vicinity of the metal foundry machine, the sensors may alternatively be placed apart from the metal foundry machine. In this case metal foundry machines producing a certain environmental disturbance may be jointly operated by controlling computer 110.
The controlling computer 110 may include a control interface for setting thershold values and functions for the respective environmental disturbances. The controlling computer may additionally include a server for hosting a control interface for displayong measurements. threshold values, functions, and or instructions and for receiving commands for setting the threshold values, modifying or setting the function, or issuing instructions via the network 140, the network 140 may comprise a LAN, WLAN, or WAN network such as the internet.
The controlling computer 110 comprises a data storage for continually storing measurements, current threshold values and functions and/or instructions in a log file. The controlling computer preferably provides the log file for display on the display 112 or on the control interface.
The controlling computer 110 may be programmed to display a 2D or 3D picture of the metal foundry and to display the respective measurements and threshold values adjacent the corresponding metal foundry machine in the picture.
The control computer 110 is preferably, as shown in fig. 1, placed in the metal foundry 2. However, the controlling computer 110 may alternatively be placed remotely from the metal foundry 2. In the latter case the controlling computer may be placed in a building adjacent to the metal foundry 2, or even further away provided that suitable communication links, wired or wireless, interconnect the controlling computer 110 with the air quality sensor 120 and the controllable valve 130.
If desired the controlling computer 110 may be programmed to, provide an alarm, either by displaying a visual cue on the display 112, emitting a sound using a speaker (not shown) or by email and/or SMS, to a worker or operator of the metal foundry 2 to alert the worker of operator of the metal foundry 2 when a measurement deviates, such as being too high or too low, from the threshold value.
Fig. 3A shows a flow diagram 200 of an embodiment of the method performed by the system 100. The steps are described below with reference to the system 100 shown in fig. 2. In step 210 the controlling computer 110 obtains a measurement from the air quality sensor 120. In step 220 this measurement is compared to a threshold value corresponding to the maximum allowable air pollution, i.e.. amount of sand dust in the air. If the amount of air pollution is above the threshold value the method obtains an instruction in step 230, which instruction is then communicated to the controllable valve 130 for increasing the amount of water so as to decrease dust formation in the shake out machine 60. In this way the air quality is maintained suitably for the workers.
A status report including the measurement and/or the result is sent to the workers using network 140 and Smartphone 150, or by display on the screen 112 in step 240.
In ease amount of air pollution is below the threshold value the methond may either go directly back to step 210, or alternatively go to step 230 but generate an instruction which causes the controllable valve 130 to remain as it is.
If the system 100 includes a water usage sensor placed so as to measure the water usage of the shake out machine 60, the method 200 may further require steps for measurement, comparing, and operating based on the water usage. In this case the above described operation of the controllable valve 130, to increase water flow to reduce dust formation, may result in the water usage fead by the controlling computer 110 using ther water usage sensor increasing past the threshold value for the water usage. In this case the controlling computer will obtain an instruction and communicate to the controllable valve 130 to reduce the water consumption. The controlling computer 110 is preferably programmed to prioritize the environmmental disturbances so that those related to worker environment, and ultimately worker health, are prioritized. Thus the controlling computer 110 is preferably programmed to keep the water usage below the threshold value for water usage only if the air quality measurement is below the thershold value for air quality. The method 200 may therefore comprise steps for measurement a plurality of environmental disturbances, comparing the measurements to a plurality of threshold values, generating a plurality of instructions prioritized according to the priority of the environmental disturbance corresponding to the instruction, and operating the shake out machine 60 only using the highest prioritized instructions for each type of instruction.
The controlling computer 110 may alternatively be programmed to modify instructions associated environmental disturbances having lower priorities so as to render them ineffective.
Fig 3B shows a flow diagram 200^I similar to fig. 3A but in this embodiment power consumption of the mould conveyor 50 is measured in step 210^I and compared to the threshold value in step 220^I. If power consumption is too high an instruction for activating the means for providing lubrication to the moulding conveyor is obtained in step 230^I and used to operate the moulding conveyor 50. A status report including the measurement and/or the comparison result is sent to the workers using network 140 and Smartphone 150, or by display on the screen 112 in step 240^I.
Fig. 3C shows a flow diagram 200^II similar to fig. 3A having the same 210 and 220 but in this embodiment if the air quality is too bad a diagnostic alarm is sent to an operator in step 250, by being sent 150, and the operator manually, instructs the controlling computer 110 to increase water flow to the shake out machine 60 in step 260. A status report is finally sent to the controlling computer for storage in step 270.
Fig. 3D shows a flow diagram 200^II similar to fig. 3A having the same step 210 but in this embodiment the instruction is generated using a function operating on the Air quality, i.e. f(A) in step 220^II. In this case the instruction is used to adjust the water flow to the shakeout machine 60, in step 230^II. f(A) may for example be water flow ≃ k * concentration of particles in the air with k as a constant. Thus where the concentration of particles in the air increases the water flow will also increase. Thus the instruction generated by the function is configured to cause a decrease of the concentration of partides in the air.
Fig. 3E shows a flow diagram 200^IV of an embodiment of the method performed by the system 100. In step 210^II a third plurality of measurements of a second plurality of environmental disturbances produced by a first plurality of metal foundry machines are obtained using a fifth of sensors such as sensors 120, 120^I, 120^II, 120^III, 120^IV, 120^V. In step 280 the sum of the third plurality of measurements is determined representing the total amount of environmental disturbance caused by the metal foundry 2. In determining the sum suitable constants may be used to transform the measurements to a common unit, such as energy, cost, etc. The sum determined in step 280 is stored in system 100, for example in computer 110.
In step 220^III the second plurality of measurements is used to obtain a fourth plurality of instructions for reducing the disturbances associated with the third plurality of measurements. These instructions are then used in step 290 in a model of the metal foundry 2 to estimate the sum of the environmental disturbances that would be the result if the instructions obtained in step 220^III were to be used for operating the metal foundry machines. The principles of this model are described above in relation to claim 5. In step 300 this estimated sum is compared with the stored sum determined in step 280, and provided the estimated sum is less than the stored sum the instructions obtained in step 220^III are then used to operate the metal foundry machines in step 230^III. If the estimated sum is larger than the stored sum the method returns to step 220^III to try to obtain better instructions. If a second, or third or fourth etc., as set by the operator of the metal foundry 2, set of instructions still do not result in an estimated sum that is less than the stored sum, then the method exits and returns to step 210^II. The second, third or fourth set of instructions may be obtained by adding a random value to the further plurality of instructions obtained in step 220^III to try to find a new minimum sum of environmental disturbances.
The instructions in step 220^III may be obtained by using thresholds as described with reference to figs 3A-3B, by using operator input as described with reference to fig. 3C, or by a function as described with reference to fig. 3D. Different measurement of the third plurality of measurements may be used to obtain instruction according to different methods, i.e. threshold, manual input, function.
As an alternative to shown in fig. 3D steps 290 and 300 may be dispensed with and the sum stored in step 280 used merely for reference or display to the workers or operators of the metal foundry 2.

Claims

A method (200) of operating a metal foundry (2), in particular a green sand metal foundry, so as to lower the environmental impact of the operation of the metal foundry (2), the metal foundry (2) comprising at least one metal foundry machine (10) such as at least one of a vertical green sand moulding machine (30), mould conveyor (50), shake out machine (60) or a sand cooler (70), said at least one metal foundry machine (10) producing at least one environmental disturbance when used in the operation of said metal foundry (2), the method (200) comprising the steps of:
i. obtaining at least one measurement of said at least one environmental disturbance (210).

ii. obtaining at least one instruction for said at least one metal foundry machine (10) on the basis of said at least one measurement, said at least one instruction being configured to cause a decrease of said at least one environmental disturbance (220). and

iii. using said at least one instruction to operate said at least one metal foundry machine (230).
The method (200) according to claim 1, said metal foundry (2) comprising a first plurality of said metal foundry machines (10, 30, 40, 50, 60, 70, 80, 90), the method being performed for each metal foundry machine of said first plurality of said metal foundry machines (10, 30, 40, 50, 60, 70, 80, 90).
The method (200^IV) according to claim 2, said first plurality of said metal foundry machines (10, 30, 40, 50, 60, 70, 80, 90) producing a second plurality of environmental disturbances when used in the operation of said metal foundry (2), step i comprising obtaining a third plurality of measurements (210^II) of said second plurality or environmental disturbances, step ii comprising obtaining a fourth plurality of instructions (220^III) for said first plurality of metal foundry machines, said fourth plurality of instructions being configured to causse a decrease of said second plurality of environment disturbance, and step iii comprising using said fourth plurality of instructions to operate (230^III) said first plurality of metal foundry machines (10, 30, 40, 50, 60, 70, 80, 90).
The method (200) according to any preceding claim, the step of obtaining said at least one instruction comprising the substep of:
a comparing said at least one measurement to at least one threshold value to obtain at least one comparison result (220), and provided said at least one comparison result indicates that said at least one measurement is not within the acceptable range defined by said at least one threshold value, either looking up said at least one instruction in at least one look up table using said at least one comparison result, obtaining said at least one instruction using at least one function operating on said at least one comparison result or said at least one measurement (220^II), or communicating said at least one comparison result or said at least one measurement to a worker or operator of said metal foundry to obtain said at least one instruction from said worker or operator of said metal foundry,
or alternatively the substep of:
b. computing said at least one instruction using at least one function operating on said at least one measurement (220^II).
The method (200^IV) according to any preceding claim further comprising the steps of:
iv. obtaining: a first sum of said at least one measurement (280) of said at least one environmental disturbance prior to performing step III.

v. obtaining an estimation of a second sum of said at least one measurement (290) of said at least one environmental disturbances, said estimation being based on an estimation of said decrease of said at least environmental disturbance caused by performing step iii using said at least one instruction, and

vi. comparing said first sum with said estimation of said second sum (3000), and where said estimation of said second sum is less than said first sum, perform step iii.
The method (200) according to any preceding claim, said at least one environmental disturbace comprising air pollution, heat, noise, CO₂ emissions, energy consumption, water consumption, or production waste.
The method (200) according to any preceding claim, said at least one instruction comprising an instruction for controlling the speed of said metal foundry machine (10) an instruction for controlling the supply of water to said metal foundry machine (10), an instruction for controlling lubrication of said metal foundry machine (50), or an instruction for controlling the operation of a means (52) for counteracting said environmental disturbance.
The method (200) according to claim 7, said means for counteracting said environmental disturbance comprising any of a heat exchanger (52) for absorbing heat, a ventilation unit for ventilating said metal foundry, and a dust filter for catching dust.
A system (100) for operating a metal foundry (2) so as to lower the environmental impact of the operation of the metal foundry (2), the metal foundry (2) comprising at least one metal foundry machine (10) such as at least one of a vertical green sand moulding machine (30), mould conveyor (50), shake out machine (60) or a sand cooler (70), said at least one metal foundry machine (10) producing at least one environment disturbance when used in the operation of said metal foundry (2), the system (100) comprising:
at least one sensor (120) configured for obtaining at least one measurement of said at least one environmental disturbance,

a controlling computer (110) configured to obtain said at least one measurement, said controlling computer (110) further being configured to obtain at least one instruction for said at least one metal foundry machine (10) one the basis of said at least one measurement result said at least one instruction being configured to cause a decrease of said at least one environmental disturbance, and

a controlling device (130) for operating said a least one metal foundry machine (2) using said at least one instruction.
The system (100) to claim 9, said metal foundry (2) comprising a first plurality of said metal foundry machine (10, 30, 40, 50, 60, 70, 80, 90), said first plurality of metal foundry machines (10, 30, 40, 50,60, 70, 80, 90)producing a second plurality of environmental disturbances when used in the operation of said metal foundry (2), the system further comprising:
a fifth plurality of said sensors (120),

said controlling computer (110) being configured to obtain a third plurality of said measurement, said controling computer (110) further being configured to obtain a fourth plurality of said instructions for said first plurality of metal foundry machines, and

a sixth plurality of said controlling devices (130) for operating said first plurality of metal foundry machines (10) using said fourth plurality of instructions.
The system (100) according to any of the claims 9-10, said controlling computer (10) further comprising:
a summing module for obtaining a first sum of said at least one measurement of said at least one environmental disturbance,

a modeling module for obtaining an estimation of a second sum of said at least one measurement of said at least one environmental disturbance, said estimation being based on an estimation of said decrease of said at least one environmental disturbance caused by operating said a least one metal foundry machine using said at least one instruction, and

a contrch module for operating said a least one metal foundry machine (10) and/or said at least one controlling device (130) using said at least one instruction if said estimation of said second sum is less than said first sum.
A metal foundry (2) comprising at least one metal foundry machine (10) such as at least one of a vertical green sand moulding machine (30), mould conveyor(50), shake out machine (60) and a sand cooler (70), said at least on metal foundry machine (10) producing at least one environmental disturbance when used in the operation of said metal foundry (2), said metal foundry (2) further comprising a system (100) according to any of the claims 9 - 11.
The metal foundry (2) according to claim 12, metal foundry (2) comprising a first plurality of metal foundry machines (10, 30, 40, 50, 60, 70, 80, 90) such as a first plurality of any of a vertical green sand moulding machine (30), mould conveyor (50), shake out machine (60) and a sand cooler (70), said first plurality of metal foundry machines (10, 30, 40, 50, 60, 70, 80, 90) producing a second plurality of environmental disturbances when used in the operation of said metal foundry, said metal foundry further comprising a system according fo any of the claims 10-11.
The metal foundry (2) according to any of the claims 12-13, said metal foundry (2) being a green sand metal foundry.
A metal foundry (2) according to any of the claims 12-14, said metal foundry (2) comprising any of a moulding conveyor (50), a pouring unit, a melting furnace, a pouring furnace or a moulding line, said foundry (2) further comprising a heat exchanger (52) placed so as to absorb heat from any of said moulding conveyor (50), pouring unit, melting furnace, pouring furnace or moulding line, and said metal foundry further (2) comprising means for converting said heat absorbed by said heat exchanger to energy for operating said metal foundry (2).