Challenges and opportunities of the traditional casting industry
Driven by the dual goals of "dual carbon" and intelligent manufacturing, the traditional casting industry is undergoing unprecedented changes. The extensive model with high energy consumption, high pollution and low efficiency is unsustainable, and the rise of the black light green sand casting workshop has opened up a new path for the industry to be green, intelligent and unmanned. Through the deep integration of automation equipment, intelligent control systems and recycling technology, this model not only solves the environmental protection problem, but also becomes the core engine of the casting industry upgrade with the advantages of "zero manual intervention and full process closed loop".
1. Core technology of the black light green sand casting workshop
1.1 Fully automatic production line: the cornerstone of unmanned production
The core of the black light workshop lies in "unmanned", and the key to achieving this goal is a highly integrated fully automatic production line. Taking the green sand high-end casting project provided by Sanzhuji as an example, the fully automatic green sand static pressure molding production line adopted by it can realize unmanned operation of the entire process from sand mold preparation, pouring to cooling.
Efficiency improvement: The production line can process 120 sand molds per hour, which is 3 times higher than the traditional process;
Precision control: The sand mold compactness error is ≤0.5%, ensuring the casting yield rate ≥98%;
Energy consumption optimization: Through the heat recovery system, the energy consumption per ton of casting is reduced by 25%.
1.2 Intelligent control system: data-driven "workshop brain"
The application of Siemens'''' high-end PLC intelligent control system in Germany enables the dark workshop to achieve "self-perception, self-decision-making, and self-execution"
Real-time monitoring: Through the sensor network, 200+ parameters such as temperature, pressure, and humidity are collected, and the abnormal response time is ≤0.1 seconds;
Dynamic optimization: The AI algorithm predicts equipment loss based on historical data, warns of failures 30 days in advance, and reduces maintenance costs by 40%;
Remote operation and maintenance: Supports centralized management of multiple workshops across regions, and the operation and maintenance team does not need to be on-site, saving 70% of labor costs.
1.3 Green sand regeneration technology: a closed-loop revolution in resource circulation
The recycling of casting sand is the core link of green sand casting. Jiangxi Lianfeng Investment Casting Co., Ltd.''''s patented technology - "Green casting sand regeneration device that can achieve rapid separation" increases the efficiency of old sand regeneration to more than 95% through three-level treatment of grinding chamber, vibrating chamber and centrifugal chamber.
Technical breakthrough: The friction design between the grinding roller and the inner gear ring shortens the sand grain refinement time by 50%, and the regenerated sand loss is ≤0.08%;
Cost advantage: The processing cost of each ton of regenerated sand is only 15 yuan, which is 80% lower than the purchase cost of new sand;
Environmental value: The annual reduction of waste sand landfill exceeds 100,000 tons, which is in line with the concept of "waste-free workshop".
2. Environmental Benefits and Sustainable Development
2.1 Emission Reduction Results: Green Revolution from Source to TerminalThe Black Light Workshop has achieved a "cliff-like decline" in pollutant emissions through process innovation:
Dust control: dust emissions are reduced by 7.52 tons per year on average;
Waste gas treatment: VOCs catalytic combustion device makes waste gas purification efficiency reach 99%, and emission concentration ≤10mg/m³;
Wastewater reuse: cooling water recycling rate in sand treatment link ≥95%, achieving zero external discharge.
2.2 Resource cycle: from linear consumption to closed-loop regeneration
Taking Jiangxi Lianfeng''''s sand regeneration technology as a benchmark, the Black Light Workshop has built a complete chain of "old sand recovery-regeneration treatment-new sand replacement":Old sand utilization rate: the proportion of regenerated sand has increased from 30% of traditional processes to 90%;
Material substitution: the use of bio-based resin binder reduces toxic substance emissions by 70%, and it can be naturally degraded;
Energy substitution: medium-frequency electric furnaces fully replace coal-fired cupolas, and carbon emission intensity has decreased by 60%.
3. Economic Benefits and Market Competitiveness
3.1 Output Value and Tax Payment: The “Real Money” of Green TransformationAfter the Shandong Xiangrui project was put into production, the annual output value reached 430 million yuan and the tax payment exceeded 20 million yuan, becoming a new growth pole for the regional economy. Its core advantages are:
Capacity release: The dark workshop produces continuously for 24 hours, and the overall utilization rate of equipment (OEE) has increased from 65% to 92%;
Order response: The flexible production line supports multi-variety small batch customization, and the delivery cycle is shortened by 50%.
3.2 Cost savings: From "energy-intensive" to "benchmark of benefits"
Labor cost: The number of workshop operators has been reduced from 120 to 10 (only responsible for monitoring), saving 5 million yuan in salary expenditure annually;Energy consumption cost: The smart grid dynamically adjusts peak and valley electricity consumption, reducing electricity costs by 30%;
Maintenance cost: Predictive maintenance reduces unplanned downtime and extends equipment life by 3 years.
