Foundry Equipment

As part of a total service covering the design, manufacture and installation of a complete range of Automated Pallet Lines, Ward provides a fast, convenient source for a full range of heavy duty rollers for pallet cars.

• Ward Flask Punch Outs are designed and manufactures as a unitized shop assembled package, pre-piped and pre-wired including pneumatics or hydraulics along with power pak and control panel. All units are shop tested prior to shipment.
• Installation: The package unit is match marked and disassembled in our plant prior to shipment, enabling fast, easy installation at the site.
• Frame: They heavy duty frame is fabricated from Heavy HEE sections, ruggedly braced and re-enforced at major stress points for long, trouble-free performance.
• Power Pak is supplied with storage tank, pressure compensating pump, hydraulic fluid filters, safety relief valve and sight level gauge.
• Hydraulic Fluid: Phosphate Ester Fluid, which is fireproof, is used exclusively in the hydraulic system of this Ward equipment.
• Control Panel: The Punchout is designed for automatic cycling with manual override. Controls include CEMA 12 panel and roller operated limit switches.
• Automated Tight Flask Systems: Ward Punchouts also form part of Ward Automated Tight Flask Systems, which incorporate Rollovers, Mould Closers, Indexing Systems, Mould Elevators, Foundry Shakeouts, Storage Systems and Flask Stripers.
• Sand Cooling Systems:
  • Ward Automatic Sand Cooling Systems was developed by Ward Ironworks for foundries with hot sand problems. It utilizes evaporation cooling to provide cooler sand while reducing the variation in water content and temperature at the sand mullor.
  • Single, Shop Assembly Unit: The system is deisgned and supplied as a complete package unit, including control panel, ready for installation on the Shakeout Belt Conveyor.
  • Installation: The "package" is quickly and easily installed. The unit is simply mounted on the belt conveyor stringers, then hooked up to a 1" water line and 110V, single-phase electric power source.
  • Operation: Water is added in the form of a heavy mist vie three separate nozzle assemblies. The depth of the sand on the belt and the temperature of the sand on the belt automatically control the amount of water added. Plows are incorporated in the system to provide more uniform cooling when the belt is fully loaded.
  • Advantages:
    • Reduces scrap
    • Reduces fluctuations in the sand moisture
    • Controls temperature fluctuations
    • Prevents over addition of water and problems with sticking in chutes and bins
• Transfer Cars: This Ward product line includes standard and custom designed units with a range of capacities and other options available to suit the customer's specific requirements.
  • Drives: Ward Transfer Car drives feature TEFC motors with clutch coupling for smooth acceleration. Worm gear reducers, heavy duty roller chain drive and an adjustable brake are designed to provide smooth, safe stopping.
  • Wheel Assemblies: All units are equipped with steel wheels with flame hardened treads, mounted on alloy steel axles and fitted with heavy-duty roller bearing pillow blocks.
  • Frame: The heavy-duty frame including operator's platform with safety rails is designed to provide long, dependable performance in Foundry and Steel Plant Service. The deck of the operator's platform is removable and is fitted with an access door for inspection and maintenance.
  • Controls: The control panel is mounted on the operator's platform and is supplied complete with a remote control push bottom station so that the car can be operated from either platform or ground level.
  • Power Source: Power is supplied to unit by cable on take-up reel mounted under the operator's platform.
  • Options: Flashing lights and horn can be supplied if required. Ward transfer cars can also be supplied with right or left hand assemblies.
• Aerators: Ward Industrial Equipment Ltd. produces a complete range of Aerators and Aerator Feeders for the foundry industry. Both units are engineered and built to provide long, trouble-free service.
  • Drives: All units feature single or double rotors with independent drives.
  • Rotors: The dual rotors are heavy duty, interchangeable and designed for long life.
  • Service Doors: Hinged service doors are designed to provide fast easy access.
  • Heavy-duty construction, including totally enclosed motors and roller bearings on all shaft assemblies.
• Aerator Feeders: These units are designed for use with Semi-automatic Matchplate Moulding Machines. In this application, the Feeder is interlocked with the Moulding Machine to provide instant aerated sand for high quality mould production. The Feeder Hopper is equipped with an adjustable gate that controls the feed rate to the Aerator. All units are available with either a right or left hand drive.
• Aerating Chutes: Ward produces a wide range of Aerating Gates with multiple shaft construction with each shaft rotating in opposite direction to the one adjacent.
  • Drives including Totally Enclosed Motor, V-Belt Drive and Drive Guard. All shafts are interlocked at the end opposite the drive with R.C. Sprockets and Chain Assembly with Chain Guard.
  • Rotor assemblies include Alloy Steel Shafting with hardened steel roll pin combining blades.
  • Service: Aerator assembly is mounted on a support frame that can be removed for easy maintenance.
  • Application: Ward aerating chutes are in operation with all types of moulding machines.
  • Ward also provides the service of assembling Aerator Rotors.

• The series of Ward Automated Pallet Lines have been designed to provide small and medium sized Foundries with an economical, automated production/handling system. These systems offer considerable cost savings over Mould Pouring Loops and in many instances can be used to replace existing overhead cranes and manually operated pallet lines. Very often, a Ward Automated Pallet Line can be installed with only minor changes to existing sand handling systems. There are three basic systems designed for use with Cope and Drag Moulding Machines. There is a Ward system suited to your requirements.

• Ward's range of services to the Foundry Industry includes the engineering, production and installation of Automated Shell Mould Systems. These systems, incorporating a variety of Ward precision engineered equipment, are designed to reduce costs and deliver new, high levels of efficiency in the production and handling of shell moulds.

• This high efficiency, Automatic Sand Cooling System was developed by Ward Ironworks Limited for foundries with hot sand problems. It utilizes evaporative cooling to provide cooler sand while reducing the variation in water content and temperature at the sand muller.
• Single Shot Assembled Unit: The system is designed and supplied as a complete package unit including control panel ready for installation on the Shakeout Belt Conveyor.
• Installation: The "package" is quickly and easily installed. The unit is simply mounted on the belt conveyor stringers, then hooked up to a 1" water line and 110V, single-phase electronic power source.
• Operation: Water is added in the form of a heavy mist via three separate nozzle assemblies. The amount of water added is automatically controlled by the depth and temperature of the sand on the belt. Plows are incorporated in the system to provide more uniform cooling when the belt is fully loaded.
• Advantages:
  • Reduces scrap
  • Reduces fluctuations in sand moisture content
  • Controls temperature fluctuations
  • Prevents over addition of water and problems with sticking in chutes and tubes

• Foundry Sand Particulators: The first stage of any sand reclamation system is to reduce the lump size. The Ward Foundry Sand Particulator reduces the sand to 16 mesh. There are 3 models, which come at 5, 10 and 20 STPH. A large percentage of this sand can be reused without any further processing since oversize material is rejected, tramp metal is removed and dust is extracted by the exhaust system.
• Foundry Sand Reclaimers: Ward designs systems and works with all types of Equipment commercially available and well proven. The Universal Sand Reclaimer offers maximum flexibility since it can operate both in the attrition only or attrition and thermal modes. This is a big advantage since the customer can start out with attrition only and add the calcining package later at nominal expense if necessary for the sand process. Capacities available include 1, 5 and 10 STPH. Of equal importance to the Sand Reclaimer is the design of the total system.
• Sand Reclaimer Exhaust System: The sand reclaimer exhaust manifold system controls the removal of unwanted fines during the sand attrition process. The fines are removed by the two stage dust collection system. The sand reclaimer exhaust manifold is adjustable to provide the correct sand classifying effect.
• Dust Collection: Any fines carried with the transportation air and collected in the bin release filter are appropriately discharged outside the silos. A two stage dust collection system right consisting of cyclone and bag filter with capacity of only 4,000 cfm for the 4ton/hour reclamation plant discharges its waste into one joint container. This box is located for easy removal and fitted with a cover to avoid contaminating the environment. To complete the safety measures, a level probe arranged within this collector box prevents dust from overflowing.
• Pneumatic Sand Transportation: The most appropriate sand handling depends on the layout. In the case of long distances and complicated routes, dense phase, full line concept pneumatic conveying is often the best and most economical solution. This concept avoids pipe wear and degradation, two of the most important features.
• Dust Removal: In order to remove dust from the return sand pneumatic conveying system or the new sand blower truck delivery system, a dust collector is located above the two sand storage silos right to filter the exhaust air. The silos are located over a high capacity sand mixer. All dust collector lines are discharged into a waste hopper at ground level for disposal.
• High Speed Vibrating Screen: This Ward product screens out the plus 20 mesh sand particulate, which is rejected. The dust take0off on the unit also removes the fine dust that is also rejected. The product of the prior step is reclaimed sand, which meets the same specifications as new sand. The screen is totally enclosed and sealed to contain all dust particles.
• Silos Anti-Segregation Device: To ensure that the sand leaving the storage silos retains the correct sieve analysis, it is important to install anti-segregation devices on all sand storage silos. The Ward anti-segregation system withdraws sand from six different bin outlets to ensure the correct sieve analysis. Without this device, batches of fine and coarse sand can be discharged separately.
• Water Cooling Tower for Sand Cooler: After reclamation the hot sand is cooled to between 85 and 90 F by the sand cooler. The water cooling, which allows the sand cooler water to be recirculated, to minimize water consumption. Fresh water is added to replace that lost to evaporation.
• Control Room: Control systems can be provided from manual to totally automated. The control room does not require an operator, at any time during the operation of the Sand Reclamation System. The printer controlled by a PLC issues a complete record of operations. It also informs in detail any abnormalities in operation by warning MIC. In the case of danger to safety, the equipment, or unacceptable sand quality, the system shuts down automatically. Simplicity of operation and safety is provided by this system, in order to achieve optimum productivity.

• 3 Models: SP30, SP60 & SP120
  • Ward Sand Particulars are designed and manufactured to provide long, trouble-free service, reducing no bake sand to -16 mesh as quickly and efficiently, plus removing any tramp metal from the sand. The discharge height is sufficient to feed a Pneumatic Transporter, Belt Conveyor or Bucket Elevator with no pits.
• Vibrators
  • The Ward line of Vibrator Motors are generously sized to give long life and trouble-free service. The vibrator is designed for operation in hot, dusty foundry service.
• Operation
  • Ward Sand Particulators are designed so that the Vibrator Motor Counterweights rotate in perfect balance with the live frame. The "Stroke Speed" combination is selected to provide the ideal "G" Force and maximum bearing life. If operated at the recommended "Stroke Speed" the equipment will provide effortless life.
• Live Frame
  • The live frame floats fully on soft, heavy-duty coil springs to isolate impact from the supporting members. The live frame itself is heavily reinforced with thick steel gusset plates. The vibrator is bolted to the live frame assembly and locked in position by Heavy Cold rolled bars to eliminate sheared stress on the retaining bolts, thereby preventing sheared bolts and elongated bolt holes. A number of deck construction options are available, but all units are supplied with a heavy-duty perforated deck plate with holes to suit the customer's requirements. Skid bars to reduce deck plate wear and side curbs are also provided combinations as required.
• Discharge Gate
  • Unit can be provided with manual or Power Operated Discharge Gate to remove tramp metal, which accumulates in the loading hopper. Discharge Height is suitable for the Tote Box or Self Dump Hopper.
• Springs
  • The highest quality spring materials are used on all models to endure long, "stand up" performance.
• Testing
  • All units are "factory tested" prior to shipment to prevent any start-up problems.

• 10 Models: FS & 2FS V 80, 100, 120, 140 and 160
  • Ward Foundry Shakeouts are designed and manufactured to provide long, trouble-free service, separating sand and castings as quickly as possible, preventing impact damage to the castings. These units are available in both Non-Discharging and Self-Discharging models and in the wide range of sizes. Various speed stroke combinations are also available to suit the customer's specific requirements. Special units designed to meet customers' specifications are available on request.
• Vibrations
  • The Ward line of Foundry Shakeouts features a two bearing design, generously sized, to give long life and trouble-free service. The vibrator is designed to grease type lubrication, with multiple groove seals for operation in hot, dusty foundry service. Maintenance was a prime consideration in the vibrator design. Bearings can be changed easily and quickly.
• Drive
  • The drive mechanism consists of a TEFC motor with a flexible shaft coupling drive or a heavy duty V belt drive running in deep groove sheaves. A special reversing drive can be supplied on larger models to reduce "start/stop" bounce. Right or left hand drive arrangement is optional on all models.
• Dampers
  • Damper assemblies are provided with all models to reduce "start/stop" bounce.
• Live Frame
  • The live frame floats fully on soft, heavy-duty coil springs to isolate impact from the supporting members. The live frame itself is heavily reinforced with thick steel gusset plates. The vibrator is locked into the live frame assembly by a heavy machined ring that eliminates shear stresses on the retaining bolts, thus preventing sheared bolds and elongated bolt holes, a common shakeout problem. A number of deck construction options are available, but all units are supplied with a heavy duty perforated deck plate with holes to suit the customers requirements. Skid bars to reduce deck plate wear and side curbs are also provided in desired combinations as required.
• Springs
  • The highest quality spring materials are used on all Ward Shakeout models to ensure long, "stand up" performance.
• Skirts
  • Removable skirts are supplied with all Ward Shakeout Models
• Vibrator Assembly
  • The heart of the Ward Shakeouts is the Vibrator Assembly, which operates on the "Circular Throw Principle" where the forces developed by the rotating counterweights are in perfect balance with the rotating forces developed in the live frame. Variations in stroke, speed, and rotation can all be made to ensure the optimum cleaning of the castings. Ward Shakeout Vibrators are manufactured in five standard sizes (80, 100, 120, 140 & 160mm.) Components for each size are interchangeable for both single and twin vibrator models.

• This unit is designed with a built in slope mounted on a horizontal support base. This ensures the correct retention time of sand and castings, breaks sand down to grain size, cools and thoroughly mixes the sand, and finally reduces the casting temperature. Drum is manufactured from heavy steel plate with replaceable wear liners and flights and is complete with heavy perforated plate screen section at discharge end to separate sand and castings. The drum rotates on forged steel heat treated steel riding rings rolling on four riding wheels all machined to exact tolerance. The riding wheels are provided with automatic graphite lubrication for long life. Adjustable thrust rollers control horizontal forces. Drive includes a TEFC motor, helical speed reducer with 1.5 service factor, as well as fluid coupling for a soft start.
• Advantages
  • Breaks down sand to grain size and is dry at 135 F to 145 F. Sand conditioning effect is superior to the competition.
  • Sand bin temperature is reduced from 185 F to 135 F. The biggest improvement is the reduction of sand moisture content, which in turn eliminates sticking and rat holing.
  • Castings can be handled with gloves since all castings are at the same temperature.
  • Reduces cleaning time by approximately 20% (both blast and manual) when compared to industry average.
  • Sprue removal is 100% with gray iron
  • Breaker Bars in Drum can be added for sprue removal on ductile iron.
  • Dust take-off will further reduce temperature of sand and casting and steaming up at feed end.

• Rotary Breaker Screens: Six Models Available: Ward Industrial Equipment Ltd. produces a series of six standard rotary screens sized to meet the normal range of foundry requirements. Each is engineered and manufactured to exacting standards ensuring long trouble-free service coupled with high efficiency in the screening, aeration and cooling of sand. There are a number of good reasons why these units are finding increased use in foundry operations across North America. Here are just a few:
  • Tapered Base: No adjustments...simply mount the Ward Rotary Screen on a standard horizontal base. Note that the motor is mounted on the same base...a completely shop-assembled unit ready for fast, low cost installation and use.
  • Removable Service Doors: Both designed for fast, easy access, cutting service time and cost.
  • Interchangeable Screen Panels: All screen panels are jig built and interchangeable, making replacement fast and easy, reducing maintenance costs.
  • Heavy Duty Components: All units are equipped with four heavyduty blades, a totally enclosed motor and heavy duty worm gear reducer. The roller bearings on the main shaft are Dodge-Timken Type C.

• Ward Standard Screw Feeders:
  • This economical Screw Feeder is available with Fixed Speed or Variable Speed Drive with 10 to 1 ratio. The drive features a Worm Gear Drive with Flange Mounted Motor rated up to 200% overload.
  • The Drive Assembly is directly connected to the screw by a Flexible Coupling and the Screw Assembly is supported by two flange blocks with anti frictions bearings.
  • The Feed Inlet is supplied with heavy 3/8" thick plate flanges to connect to storage hopper.
  • Discharge outlet is equipped with an Air Cylinder and Solenoid Valve which automatically opens and closes when the feeder starts and stops. This ensures positive cut-off of material flow.
  • Outlet can be provided with standard pipe diameter or optional bolted flange.
  • Specifications:
    • The screw conveyor is one of the most economical conveyor types available for moving bulk materials. It is completely enclosed to contain the moving material. The standard unit, with variations in design, is suitable for solving a variety of bulk material handling problems.
    • The Complete Screw Conveyor Unit is supported by the trough end and by either Feet or Saddles at intermediate locations.
    • Trough Ends support the conveyor drive and ends shafts, and maintain trough alignment. May be furnished with choice of bearings.
    • Troughs and Covers completely enclose the material being conveyed and the rotating parts. Covers are available in various types and are secured to the troughs by bolts. Clamps may be used instead of bolts, depending on the trough cover combination used.
    • Inlets and Discharge Openings may be located wherever needed. Discharge spouts may be without slides or fitted with either flat or curved slides. These slides may be operated by hand, rack and pinion gears, or by power.
    • The Conveyor Screw imparts a smooth positive motion to subsequent screw sections. Held in place by high strength coupling bolts.
    • Hangers provide support, maintain alignment and serve as bearing surfaces. Bushings are available in Hard Iron, Thordon, Bronze, Oilite, Stellite, Wearrite, etc.
    • Shaft seals can be furnished with waste packing seals, packed gland seals and plate seals for anti-friction bearings.
    • Drives are normally Shaft Mounted Helical Gear Reducers with TEFC Motor, V-belt drive and drive guard. Special drives can be furnished to customers specifications.
    • WARD Engineers can also design special screw conveyors to suit your application. Contact us we will be pleased to assist you.