Leadshot machine works with melted lead. So it is basicly a casting machine. Two important points need to be followed; heat levels and melted metal.
The machine is equipped with a touch screen control panel. This panel allows to control heat levels and start/stop of several units.
The controlled heat levels are;
*Heat level of melting pot by controlling the burner
*Heat level of operating mold by controlling the resistant
*Heat level of back-up mold by controlling the resistant
*Heat level of water tank by controlling the resistant
*Heat level of dryer by controlling the resistant
The controlled start/stop units are;
*Graphite Coating Tumbler
Beside this touch screen control the operator is able start/stop and adjust the speed manuelly. The buttons are on the wall of elevator, beside the mold. Operator can do;
*Start/stop the pump
*Start/stop the vibrator of the mold
*Adjust the speed of the pump
*Adjust the speed of the vibrator of the mold
*Fill the water tank by open/close the valve
Now let's see the sections one buy one:
Burner; The machine can use several source of energy; oil/gas/fuel. At first the type of energy source need to be set. Afterwards the burning level of the burner need to be decided. It is better not to change the setting and keep it constant after installation. The most critical point is the pureness and the pressure of the gas. It may cause some damages if not good quality.
Melting Pot; Lead has a melting point of 324 degree celcius. The heat level may varry between 380 and 420 degree. Never drop water on the melted lead. It may cause explosion of lead. Melted lead turns into leadoxide on the surface of the melting pot. Leadoxide has a much higher melting point than lead. So this turns into drust. Time to time this drust need to be taken out from the surface of the melting pot. This drust still contains high level of lead which can be recycled and gained again by high heat level melting pot.
Pump: Inside the melting pot there is a special pump which can work in melted lead. The function of this pump is to fill the small upper lead tank which lead is poured onto the mold. This pump is controlled manuelly. The speed adjustment of it is very sensetive, be careful by changing the speed.
Mold: The heat level of the mold depends on the diameter of leadshot desired. The nozzles of the mold will get blocked meanwhile. This blocking time depends on the quality of the lead mainley. As stated before lead has tendency to turn into leadoxide. Also if the content of tin is high this is another factor to block. Mold is a four layer structure. The combination of layers decide the diameter of the leadshot.
Water Tank: The heat level must be between 89-91 degree celcius. Beside that the PH level of water is important. There are special devices and chemicals to keep the PH level constant. Inside the water tank there is a special wood plate with a specific angle. It is very important to keep the wooden plate clean and smooth surface. Time to time the bottom point of the water tank need to be cleaned.
Elevator: Elevator moves in a special tank. This tank is also filled with water which is connected to the main water tank. 30 minutes before the operator starts to work it is better the elevator turns on. By this way cold water in elevator will mix in the hot water in the main tank and the heat level will get homogene. Time to time the bottom of the elevatro need to be cleaned. Be aware the elevator doesn't big lead parts like stones. This may damage the caps ot the elevator. Worst case can damage the chain of the elevator.
Dryer: The heat level of the dryer must be 100 degree celcius. After the heater of the dryer opened better not to delay to give movement in the dryer so the lead inside wouldn't melt.
Mirror: Mirror need to be set in correct angle to allow good round leadshot passes and the defect ones drops into defect pool. Once the setting is done no need to change.
Graphite Coating: It is critical to have correct amount of grahpite powder in the coating tumbler. If less the leadshot will not become shiny. If more the color becomes mate grey.
Seperator Sieve: Each sieve is changable. No need to change if it is not broken or any other diameter of sieve required.
As a summary the leadshot machine is a complete units which just requires lead ingot. All melting, casting, rounding, drying, selecting, coating and seperating processes done automatically. Operator must try to experience the correlation between these steps.
Data: 11 February2019
Lead is our business
MTM ENGINEERING & CONSULTING
Mustafa Kemal Pasa Mah. Dumlupinar Blv. A Blok No.266 A/82
06530 Cankaya, Ankara, Turkey
VAT Number: 118 260 75998