up next to existing facilities, Koyama was able to work from a blank sheet of paper. “We wanted to build the best,” said company President
Takahiro Koyama through an interpreter. “We wanted to streamline labor and optimize technology and environ- mental controls.” Te new iron plant (Fig. 2) is built around an Ace-5 tight flask molding system from Sintokogio Ltd., Aichi, Japan. Te mold size is 1,000 x 800 x 280/280 mm, with a mold produc- tion rate of 120/hour. Te molding system uses aerated sand filling and squeezing in conjunction with servo cylinders for the mold handling lines. With the new mold line, Koyama has reduced as-cast wall thicknesses to 2.5 mm and draft angles to 0.5 degrees. Koyama also utilized Sintokogio to engineer and
integrate the auto-pouring system for the mold line, auto-handling system for the ladles from tap out through magnesium treatment to pouring, sand system, and mold conveyor and cooling line. Tis integration is what allows for labor maximization from tap out of one of three 4-ton induction melting furnaces (the original iron foundry uses cupola melt) through shakeout. Prior to adding the new iron facility, Koyama’s total pro-
duction was 4,300 metric tons per month. In 2010, the firm averaged 5,500 tons per month.
Advancing Cleaning & Finishing
Automated casting grinding systems have been designed for job shops to improve the consistency, effi- ciency and quality of castings leaving the cleaning room. In addition, these systems replace the labor requirement
Koyama: Not Just Iron While Koyama has advanced the technology in its iron
facility, the aluminum casting plant is high on automation as well, particularly for a job shop. Utilizing a combination of permanent and semi-permanent mold casting cells, the firm casts via gravity and tilt pour systems. For all cells, the metalcaster employs robotic pouring.
“我们想做最好的，”公司总裁Takahiro Koyama 通过翻译说， “我们希望简化劳动，优化技术和控制 环境。”
新的铸铁车间（图2）是围绕着日本爱知县新东有限 公司提供的 ACE -5静压成型系统。铸型尺寸为1000 x 800 x 280/280 mm，生产速度为每小时120型。该 造型线采用充气填砂和伺服气缸挤压的方式。有了新 的成型生产线，koyama公司可以把铸件壁厚减小到 2.5mm，把铸件的拔模斜度减小到0.5度。 Koyama公司同时利用新东公司设计和整合了造型线 上的自动浇注系统、孕育处理到浇注的钢包自动处理系 统、落砂系统和铸型输送与冷却生产线。这种集成使得 劳动力效率最大化，在经济衰退期省去了三台4吨感应 熔化炉中的一个。原铸铁车间使用的是冲天炉。 在建新的铸铁车间之前，Koyama公司的每月总产量 为4300吨。 2010年，该公司平均每月生产5500吨。
先进的清理系统
车间设计了自动化铸件打磨系统，改善了清理车间铸 件的一致性、效率和质量。此外，这个系统替代了铸造 厂最艰苦部门之一的人工需求。 对于Koyama公司，外部供应商的自动化设备太昂 贵，或者技术不适合铸造环境。因此，该公司自己开
Koyama公司：不仅仅是铸铁
Koyama公司在改进铸铁车间技术的同时，铝合金铸 造车间自动化程度也很高，特别是工作车间。结 合压铸与半固态铸 造，Koyama采用重 力与倾斜浇注系统来 浇注。对于所有铸造 单元，铸造厂都使用 机器人浇注。
Pictured is a casting cell with robotic pouring for cylinder heads in Koyama’s aluminum casting facility.
图为Koyama公司铝合金 铸造车间浇注气缸盖的机 器人设备。
Fall 2011
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 35
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