Special solutions for tap valve production at ELAFLEX Design and manufacture of rail track and two crane foundry ladles
How does the fuel nozzle know when the tank is full?
Have you ever wondered about that? Put simply, there is a small tube inside that sucks in air. During refuelling, air flows through this small tube because the tank is not yet full. Once the tank is full, the air supply is blocked. The negative pressure activates a mechanical device in the valve that stops the flow of fuel – and the nozzle makes a ‘click’ sound.
The aforementioned nozzle that we use at the petrol station most likely comes from ELAFLEX HIBY GmbH & Co. KG. The company is a leading international specialist in refuelling technology and secure connections for the transfer of liquid, gaseous, and sensitive media. This includes hoses, fittings, couplings, expansion joints, and, of course, nozzles. At its production facility in Plettenberg, ELAFLEX manufactures these in various designs. Recently, two innovative crane foundry ladles have been used in the casting process – designed and produced by Blumenbecker.
Construction of telescopic casting hangers with bogies for red brass and aluminium casting
A crane foundry ladle is a technical lifting and carrying element used in the casting of liquid metal. The two new designs from Blumenbecker are telescopic via electric chain hoists. In addition, there is a power-driven bogie for holding the crucibles. The telescoping and the bogie are controlled via a control panel on the crane foundry ladle.
The two technical devices are quite something. One is for casting gunmetal, which is a special copper alloy. Gunmetal is used for components that come into direct contact with fuel (petrol/diesel). Its melting point is over 1,000 degrees Celsius. The other is for casting aluminium, which is used for the housing. Here, the melting point is ‘only’ around 300 degrees Celsius. Monday is gunmetal casting day. From Tuesday to Friday, aluminium is cast. Fortunately, today is Wednesday. ‘It's almost cold in here,’ smiles Philipp Lietz, production manager at ELAFLEX and responsible for production, maintenance and everything related to the foundry since 2016.
Ergonomic controls for safe and efficient operation casting hangers with push button
The foundry is cramped. Everything has its place, otherwise the processes would not function. Sunlight streams in through the skylights. The many lamps provide additional lighting for the hall. It is bright, hot and loud. The smell of molten metal hangs in the air – somewhat pungent, but slightly sweet.
The employee in protective clothing controls the crane foundry ladle by hand using the ergonomically shaped handles.
The liquid aluminium is in the large crucible (approx. 70 cm high and 50 cm in diameter), which hangs directly in front of him on the pipe construction. At the touch of a button, he can tip the red-hot crucible and the aluminium flows into the moulds, which will later become the nozzles. With the old crane foundry ladle, he still had to operate a hand wheel to move the crucible, which weighed up to 120 kg. On red casting days, the crucible can weigh up to 300 kg.
Customer voice:
‘This is a very special project that requires a clever mind. It's not an easy topic, and Blumenbecker has mastered it well.’
Philipp Lietz, Head of Production, ELAFLEX HIBY GmbH & Co. KG
Manufacture of a monorail with curved track and electric switch
Blumenbecker not only supplied the two crane foundry ladles, but also renewed the entire casting line. Now there is a monorail with curves and an electric switch. "The whole project was a challenge. Anyone can build a straight crane runway. And then the standard for moving molten masses changed. Our designs had to be designed for higher temperatures than originally assumed," reports Pascal Laser, Head of Industrial-Services at Blumenbecker in Beckum.
It took around two years from the order to installation. Designs were created, agreed upon and optimised. ‘For a quality product like ours, casting pressure is essential. It must be cast evenly. The equipment has to be right, and Blumenbecker has found a good solution,’ confirms Lietz. An employee operates the crane foundry ladle up to 3,000 times a day. The processes and the employee's experience are just as important as the feel and layout of the buttons.
Casting hangers with electric drive
Previously, employees had to pull the crane foundry ladle themselves. Now, this work is done by a drive, which is a real relief. The device is also easier to maintain and subject to less wear and tear. ‘This is a very special project that requires a clever mind. It's not an easy task, and Blumenbecker has mastered it well,’ attests Lietz. Two weeks were scheduled for the rebuild.
"The technicians on site were a well-coordinated team. In the end, they finished two days ahead of schedule, so we were able to use the time for adjustment work," he says happily. And when maintenance is due soon, the Blumenbecker technicians will take care of that too.‘Click.’ The tank is full. The next time you stop at the petrol station, you might also think about how the fuel nozzles are made – including the crane foundry ladles.
