12/23/2009 - Custom Rail Scale

A foundry in Birmingham, Alabama wished to weigh molten metal as it was poured.  This idea came with many complications.  First, molten metal will destroy virtually everything in its path, especially expensive electronic equipment.  The scale components, and even its deck, must be extremely heavy-duty, and must be protected with fire protection material.  This was not a problem for Mettler-Toledo and Birmingham-Toledo.  Mettler-Toledo, as always, provided heavy-duty equipment, and Birmingham-Toledo, with its great experience in the foundry industry, provided expert knowledge regarding further protection against molten metal.

On to the next problem - the area involved included two sets of rails.  One set of rails came from the east and included standard 115 pound rail.  The other set of rails came from the west and utilized a smaller rail car on 80 pound rail.  Both set of rails crossed the pouring area.  Birmingham-Toledo suggested a custom rail scale with both size rails.  Foundry engineers and Mettler-Toledo engineers worked together to ensure that the custom scale with four independent rails was sized to perfection.

Next problem - the rail scale needed to fit into an existing pit.  The pit was very wide, but not deep enough for a rail scale.  Again, the two companies' engineers worked together to provide drawings of the existing pit and the required modifications for the new pit.  Jett Construction provided excellent craftmanship in reconstructing the pit to allow for the custom scale.  However, the existing pit was still very wide, and the outside areas needed to be covered so that molten metal would be impeded from entering the pit.  Mettler-Toledo's engineers provided additional drawings and fabrication of heavy-duty walkways to cover the outside area.

Along with all of the ideas, Birmingham-Toledo's Master Technicians, Arnold Kilgore and Greg Doss, provided full installation, calibration, and commissioning of the custom scale.  The Mettler-Toledo fully digital, MTX 200,000 pound load cells were specified and installed.  Birmingham-Toledo also specified and installed an IND 780 controller with digital POWERCELL technology and Ethernet TCP/IP, as well as MODBUS TCP.

The use of this weighing technology will allow the foundry to save millions of dollars through elimination of waste.  The heavy-duty Mettler-Toledo equipment will provide decades of problem-free operation.  Birmingham-Toledo's ideas and innovation have given the foundry an edge up on their competition and will continue to provide years of state-of-the-art maintenance and service.

The custom weighbridge is installed

Four rails on a single scale

Installed with custom walkways

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