The Palmer Carousel Molding System (CMS) has been developed to provide a high volume molding alternative to conventional conveyor loop systems. Its unique, self-contained design provides complete No-Bake molding capability without additional equipment and with minimal floor space requirements.

The PCS is based on the concept of dedicated workstations. Each station is complete with its own variable force vertical vibrator and 180° hydraulic actuator. The variable force vibrator provides both compaction and draw forces while the actuator inverts the station at the time of draw, thus eliminating the need for a expensive rollover / draw machine.

Station Design 

Each station begins with a cast iron platen that serves as a mounting point for both the vibrator and tooling.  The platen is available in three standard sizes and is engineered to allow for deep molds.  Mold sizes are: 
  

Model	Maximum Size	Minimum Size
CMS-30	24”L x 24”W x 20”D	12”L x 12”W x 4”D
CMS-40	34”L x 34”W x 30”D	22”L x 22”W x 6”D
CMS-66	60”L x 60”W x 36”D	40”L x 40”W x 8”D

These sizes are the maximum each platen can accommodate.  Custom mold sizes can be accommodated based on customer request. 
 

The CMS is designed to include six, eight, or twelve stations.  The number of stations is determined by the production rate, cycle times, number of tooling charges, chemical system, etc.  A recommendation will be made after customer requirements have been determined.

Palmer Carousel Molding System Video

Tooling Requirements 

The PCS will accept most flaskless No-Bake patterns up to the maximum platen capacity.  Various mold depths can be accommodated with jump assemblies that will keep the overall pattern heights within a predetermined design window. 

A common, positive lock, cast aluminum base mounting plate is used for all tooling.  This simplifies and expedites tooling changes and clamping, as well as providing a positive location for automatic mixer operation.  Manual and semi-automatic pattern changing options are available. 

SM-Series Mixers 

The SM-Series Mixer features a unique sliding mixing chamber, which replaces conventional double pivot mixer designs.  They are used as an integral part of the CMS because of the excellent X-Y axis control and superior area of coverage. 

When compared to traditional single or double pivot mixers, the SM-Series eliminates the need for an operator to push or manually move the sand.  Joystick operation allows the operator to place sand exactly where it is needed with no manual effort.  Automatic operation can be timed to eliminate excess strike-off sand waste. 

The capacity of the mixing chamber used will be determined at the time of system design based on mold size and production requirements.  The capacities range from 200 to 4000 pounds per minute. 

Dedicated Vibrator 

Each station is equipped with an adjustable vertical force electric vibrator.  This vibrator is programmed to provide one force for mold capacity and another force for the draw station.  Vibrator forces can be manually controlled by the operator or automatically determined by the PLC controller. 

Mold Strike-Off 

Mold strike-off occurs at the first station after the mixer.  Strike-off can be done manually or with an optional automatic strike-off unit.

Dedicated Hydraulic Actuator 

An onboard, oversized hydraulic unit powers the dedicated hydraulic actuators at each station.  The actuators provide 180° rotary movement when the station enters and leaves the draw station.  Each actuator is individually controlled by the PLC and includes positive cushioned stops that control home and rotated positions. 

Mold Draw Lift Table 

Mold drawing from the inverted station is accomplished with  heavy-duty scissor lift table equipped with a powered belt conveyor top.  The table lifts until contact is made with the mold.  Proof of draw is provided to ensure the mold is received from the pattern.  Once lowered, the mold is conveyed out to the customer’s mold handling system.  A secondary lift table may be secure to reach the discharge conveyor height, depending on final system design. 

Pneumatic or hydraulic mold pins can be used to retain the mold in the inverted pattern until the lift table has achieved contact.  Once contact is made, these pins automatically retract and allow the table to lower the mold from the pattern. 

Control System 

The PCS control system will be offered in two PLC based forms: 

MANUAL – This is the base control package offered with any of the CMS systems.  It is a manually controlled system, which will require operator activation of each mixer and carousel function. 

A mixer control station will contain pushbuttons and switches for all mixer operations, including a four-way joystick for mixer movement.  This station will also include controls for compaction, optional strike-off, and carousel rotation. 

A draw control station will contain pushbuttons and switches for the follower, lift table, and exit conveyor functions.  An automatic proof-of-draw cycle is included.  Safety interlocks will be provided through the PLC to prevent carousel rotation before the draw cycle is completed. 

AUTOMATIC – This optional control package governs all aspects of the system operation and removes the operator from the production cycle. 

A “Teach Mode” is used when a pattern is first introduced to the PCS.  The control system is taken through the learning process in which all parameters for that parameter for that particular pattern are determined.  These include: 

• Mixer fill pattern

• Amount of seconds of facing resin levels

• Amount of seconds of backing resin levels

• Whether or not iron oxide is needed and when

• Force and duration of compaction vibration

• Force and duration of draw vibration

• Any special dwell times needed to set riser sleeves, gagers, etc

After this initial training, anytime the pattern is returned to the carousel, the operator will key in the serial number of the tool and the quantity required.  The PLC will then recall the production specifications and manufacture the quantity desired. 

The Carousel Molding System has been designed with the ruggedness and simplicity that have been our trademark from the beginning.  Many of the specific details of each system will be finalized with each customer based on their individual requirements.

No-Bake Foundry System Specification Worksheet
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