The present in v ntion concerns a Method of operating a metal foundry, in particular a green sand metal foundry, and a system for performing the method. The present invention further concerns a metal foundry comprising he system.

Techniques for automatic operation of foundries am. known. US$.125448 discloses an automatic foundry plant in which information co cerni g the characteristics of each Indi id- ual mo ld is sensed in the moulding machine and used in a downstream pouring unit for controlling the pouring of molten metal into -he mould to which the information relates. The information is disclosed as relating to the type of mould, whether cores haye been placed in the mould, whether the mould Is suitably firm, and whether the mould ^' is .unsuitable for pouring due to other reasons. Using t is information the pouring unit may be -controlled to properly position: the pouring nozzle in relation to the mould, or to not pour the specific mould to which the information relates, information, regarding whether a specific mould has been poured or not, as well as information regarding the weight of t specific mould, ma then .be provided by the pouring unit and used to control ^" a water dosing: unit for ensuring a proper amount of water in the moulding sand leaving an extraction station where the- mould is broken up,

The method described in LJS5125448 does not minimize, nor measure, the: environmental disturbances: caused by the foundry" operation,..-rather it focuses solel on ensuring a fault free operation based on information concerning fhe _: -.characteristics of each individual mould.

Further, O89 09666 discloses a method nd apparatus for evaporative casting.. An evaporative pattern is positioned in a. -container. Moulding; medium is compacted around ^' It and the container is positioned under a pouring nit. As molten metal pours Into the container and evaporates the pattern the gases generated by the pattern are evacuated using a vacuum pump.. Pressure within the container is measured by pressure probes and used to control a modulating valve -and a vacuum surge vessel connected to the pump. By controlling the pressure the flo rate of the molten metal Is controlled. The method described In

WQ8 09686 does not minimize, nor measure, the environmental disturbances caused by the foundry operation, KR2S3-1 GQ55925 discloses a local ventilation device and a multi-hood local ventilation method tor fluctuating sir pollutants,

DE102O090315S7 discloses a met od of eolteding heat from a strand casting process using a heat exchanger.

Metal foundries have in recent years become more f ocussed on environmental disturbances correlated )mth foundry operation due to the increased focus on such environmental disturbances and challenges of today ^' s society and the need to provide a suitable environment for the: workers of the metal foundries, disturbances related to the operation of a me al foundry include air pollution, C0 ₂ emissions, heat, noise, energy -consumption, wafer con- sumption, and: waste products such as spent sand, spent benfonite clay and discarded castings. Spent sand and foenfonite day cannot be recycled but must be discarded.

Further waste products include metal parts which a e: not part of the final casting hut ^' hich form i feeders and risers, i,e, reservoirs in the mould, which are used to ensure a proper easting and solidification of the molten metal and are separated from the casting once if the casting has been separated from the mould..

Further raw ^" materials _. , used for the operation of the metal foundry, which may be seen as environmental disturbances include consumption of metal, consumption of new sand and new bsntoniie clay, consumption of any additives used to form the green sand and consumption . of pressurized air or steam for running machines or providing heating.

Each of these environmentai disturbances is related to one or more: unit operations in _. the metal foundry. As an example green .sand foundry moulding, In which moulds or forms made from sand are used, broadly employ the unit, operations of providing green, sand, forming the green sand info a green sand mould, pouring molten metal into the green sand mould, allowing the molten metal to solidify, removing the green sand mould from the ©as!-- lug, and conditioning the green -sand for reuse.

Air pollution, in the form of dust and fine particles, is typically related to. the unit operaticns for .handling and using the green sand, i.e. providing, forming, and removing. Further, where the sand used comprises silica sub micron sized silica particles: may be formed when the sand in the moulds are contacted: by tine rnolten metal during pouting of the molten meta! into the moulds-. Such particles may lead to silicosis in the workers, ©taiie.undries ihere fore need to spend a considerable effort on dust collection, The dust caused by different unit operations in the metal foundry are of different substances and different compositions and may for -example contain, metal or etal oxides:-.-

Air may also be polluted with combustion products, such as carbon monoxide, and/or volatile organic compounds VOC),

Many unit -operations in the metal foundry produce odours or fumes both in the interior environment, i.e. ithin the metal foundry, and the exterior environment 1 e. the environment outside the metal foundry. These odours and fumes may fee unpleasant or harmful to inhale. Ai i the environment outside the metal foundry ma also be polluted b sulphur dioxide and nitrogen oxides from the fuel, such as coai, oil or gas, used to heat, the furnaces used for melting the metal. If the metal that is to he molten comprises pieces of scrap metal or recycled metals, paints and coatings on the pieces of metal may result in the pollution of the air in the metal foundry with. or example djoadns, Also finishing treatment of casting such as g rinding- a nd ¾ve ids ng may r lease -toxic m eta I p art ides into th e air.

Heat is mainl related to the unit operation of pouring the molten metal and allowing it to solidify. Heat is further released from the fameee used for melting the metal Heat may cause: dehydration, heat cramps, heat exhaustion and heat stroke In workers, in a laundry. orkers may also develop eye cataracts from Infrared and ultraviotet radiation emitted from the rnotten mefat Splashes and sparRs from: the molten metal may also cause burns,

Noise may be related to an unit operation and ma be of ^' -short duration, suc as from impacts, or longer duration, such as th noise from a shake out machine. Most common noise sources are from moulding machines, shake out machines,: and finishing operations such as shot blasting, arc gouging, -fettling end. dressing of castings. The noises generally range between about 80 and 11 QdB(A), however some noise may be as high as i 18dB{A). Another noise source is noise from using compressed air for cleaning moulds or for introducing mould .material into the moulding machine, Although personal hearing protectors are available ¾ ^' is common to not use them: for noises of short duration, however the short duration: noises add to the oYeralhexposnre, i,e, the overall -environmental impact on noise.

Closely related to noise is vibration which w y affect not only worker health but also the longevity, performance and maintenance requirements of the metal foundry machines, thereby ultimately affecting the efficiency of the metal foundry.

€0 ₂ emissions are typically related- to the energy needed for melting tbe metal to be used in the foundry and the. energy needed for running -the machines, e.g. the sand moulding machine, the mould conveyor, the shakeout .machine- or the sand cooler, needed fo performing the unit operations. Further energy is needed for providing ventilation of the metal foundry.

Consumption, of water is related ^' to removing the green sand from the castings, to conditioning the sand to provide a good mouidabliity of the send when moulded in the sand moulding: machine, for limiting dust formation at for example the shakeout machine, and for cooling.

Further, the consumption of water often results In waste water which need ^' s to he taken care ^' of properly. The waste water may for example: contain metal dust or- organic- compounds. Waste water -may also be caused by storages for metal scrap storing of slag on the ground outside .the metal foundry due to rain -water taking up pollutants from the scra metal or slag and seeping: info the ground.

All unit operations require energy to he performed.

Production waste is related to the unit operation of forming the -sand, pouring the molten metal , removing the casting from the mould,, and conditioning the sand for reuse. Production waste is further related to controlling the eastings to detect defect castings which must b scrapped, I.e. which are casting scrap. Scrap can often he remeited, and that goes for slag too, however, in some eases slag has to be disposed of in a landfill.

Of t os environmental disturbances, air pollution, heat, and noise primarily affect the worker environment whereas C€½ emissions, energy consumption,: water consumption and productio waste primarily affect the environment surrounding, the foundry. Energy con- sumption, a er consumption and production waste fudher affects the cost of running the metal foundry operations.

Further elaboration on the environmental impact of metal foundries is found in; the report "integrated Pollution Prevention and Control Reference Document on Best Available Techniques in the S itberies and Foundries industry" July .2004, froffit:the European !PGG Bureau.

To: rrwii ize the impact, associated with operating: a metal foundry, on the environment C€¾ emissions, energy consumption, wate consumption and. production waste should preferably be as ½w as possible.

Further, in order to provide a suit ble worker enyiron entfer the workers in the metal foundry, the air pollution and noise, should be kept, as low as possible and steps be taken to pre- vent the t at fro causlng too hig a temperature in: the foundry.

At the same-time the metal, foundry, must fee run so as to rovide an efficient production of castings. For exa le the number of castings which are defect and must be scrapped must be as tow -as possible so that the number of useable, i.e. proper, castings per unit of time and amount of environmental disturbance is a high as possible. This is because scrapped _: castings, which must be discarded or re-melted, represent production wast if discarded and require energy, i.e. heat, if re-melted. Further, eve where the Casting can be machined to a . -proper casting, for example if the casting is slightly defect due to mis-match oftbe mould halves resulting in a defects in the casting adjacent toe parting lines of the mould, such machining or fettling requires both ene gy: and labour and may expose workers o operator of the. metal foundry to a difficult or unhealthy work environment. Thus keeping the num be of useable, i.e.; .proper, castings per u nit of time and amount of en vironmental disturbance as high as possible, minimizes at least those environmental disturbances related to scrapped castings and energy for re-melting.

If is therefore Important to obtain a good interior environment, i.e. a lo level of environmental disturbance on the. workers in the metal foundry, arid a good exterior environment, he. a low level of environmental disturbances on t e environment outside the mefal foundry. Further the tots i level of environmental disturbances to the interior environment and ^; the ex- ferior environment should be as Sow as possible. 8 f is therefore an object of the present invention to provide a met od of operating a metal foundry in whic environmental disturbances are minimized white still providing an efficient production of castings.

It is a further object o! the present invention to provide a system for performing the method of operating (he -metal foundry.

It is yet a further object of the present invention: to provide a metai foundry comprising the system.

It is yet a further object to provide a method of reusing heat caused by the operation of a metal foundry.

At least one of the abo objects, or a least one of an of the further objects which will be evident from the below description, are according to. a first aspect of the present invention achieved by the method according to claim i .

By .operating th metai foundry machine using at least on instruction obtained po th basis of the at least one measurement, the at least one instruction being configured, to cause, a decrease of the at least one environmental disturbance, it is ensured that the metal foundry is operated so as to lower the impact on the environment from the operation of the metal foundry.

By operating the metal foundry so as to lower the.enwonroental impact of the operation of the metal foundr the operation of the rn eta! found y is also at least. artly optimised.

In th context of the present invention lowering the environmental impact of the operation of the rnetal foundry refers to lowering: the environmental ^' . _. .disturbances caused by the at least one metal foundry machine, and accordingly by the operation of the metar foundry, .in the vicinity of the metal foundry machine, in the metal foundry, and/or in the environment Thus lowering the environmental impact of the operation of the metai foundry is beneficial to both the workers: and operators; of the metal foundry and the environment..

Th metal foundry is: preferably a metal foundry performing casting of metal using green sand mouids, however other types of mould material is possible-.. The metal foundry machine may comprise a green sand storing and providing machine, a moiling _, machine such as a vertical green sand moulding machine, a flask moulding: machine, match late moulding machi e, a core shooter machine, a mould conveyor or moulding line, a pouring unit, a shakeorji machine, a sand cooler, and a easting clean log and treating machine etc. Generali the metal foundry machine may comprise any niachine used i ^' ri.a metal foundry for the metal foundry operations

Further the at least one metal foundry machine may comprise a yeatilatio-n d viee. The steps of the method defined in claim 1 should be performed in the order oi l 11, jii.

The at least one ^■ .■measurement may b uantitative sue!) as a number or value,, or .-qualitative such as a Boolean value. The at feast ene measurement ma he obtained in the metal foundry machine, In the vicinity of the metal foundry machtnei e.g. besides, above etc., within the metal foundry, i.e. within the building housing the metal foundry machine, or outside the metal foundry,

The at feast one measurement may be a measurement of the amount, intensity, occurrence, extent, or concentration etc of the environmental disturbance. One example Is the measurement of usage of power for a certain metal foundry machine.

The- measurement may be a direct: measurement of the environmental disturbance produced by the metal foundry machine, or a indirect measurement of. the environmental disturbance, that is a measurement of an environmental parameter Influenced by the environ- mental disturbance, As, an example air pollution is typically due to- dust formed during handling of th green: sand or other mould material. Dust may be measured by a direct measurement, e.g. by measuring the amount of dust particles caught, in a filter or on a charged membrane during a speei- fled time. Dust may also be measured: by indirect measurement by measuring how much light emitted from a light source is- eceived by a photo detector.

Where multiple measurements of the at least one environmental disturbance are measured, such as multiple measurements, of ^' -air pollution from different positions In the metal foundry, these multiple measurements ma be combined with measurements .from ^' other sensors indicating flow of sir ^' the metal foundry into a ^' 0~rodd i far extrapolating the air pollution, at an point i the metal foundry

Thus the measurement may be obtained directly by a sensor , thus resu ting in a measurement of the environmental disturbance in the position of the- sensor. Alter atively the measurement may be obtained at a desired position, which, there is no sensor, by using sensor data from a number of sensors at different positions and extrapolating the measurement in for the desired position from the sensor data-.

The at least one Instruction is configured to cause a decrease of the at least one environ- mental ^' disturbance, in other words the at least one instruction is suitable for causing a decrease of the at least one environmental disturbance. This means that the at least one Instruction is one which, h n used to operate the at least. one- metal foundry machine, is determined empirically or analytically: to cause a decrease of the at least one environmental disturbance. Thus there is an empirical or analytical or logical relationship between the at least one instruction, the at least one metal foundry- ^' machine,, and the- a least one environmental disturbance. The relationship between the at least one environmental disturbance and the at least one instruction causing a decrease of the environmental disturbance may be determined empirically,, by operating the at least one metal foundry machine under different conditions, using different instructions, and obtaining at least one measurement of the at least one environmental disturbance for each of the different condition. Th relationship may also be determined analytically or logicall by considering how and why the at least one environmental disturbances is produced by the metal foundry machine. As one example if may be readily empirically ^• •determined that spraying water onto dust generating unit operations, such as the shakeouf machine, reduces dust, thu increasing; the amount of water sprayed will result in decreasing the amount of dust formed.. As another example It may readily be analytically of logically- determined that decreasing, the speed of a moulding conveyor decreases the noise caused by running the .moulding conveyor.

In the context of the present invention the term obtaining is to be understood as also comprising the terms determining- nd calculating.

Using the at least one instruction may comprise eonf rolling the at least one metal foundry machine directly, i.e. via the at least one metal foundry machine ^' s control interface or control computer, or indirectl b controlling an external source, such as a source..of wafer, >■ power, pressurized air etc., to which the at least one me al foundry machine is connected for receiving said water, power,, pressurized air etc.

The at least one instruction may be used ½ operate the at least one metal foundry machine § by being used to control a supply of a medium to the machine, e.§. _: control a valve for delivering water to the metal foundry machine, contfoithe speed of the motor of the least one metal foundry machine.

Where the at least one meia] foundry machine produces more than one environmental, dis-0 furbanees these more than on environmental disturbances are often of different types. It is however contemplated within the context of the resent invention that th more than ohe environmental disturbances produced by the at least one metal, foundry machine may he of the same type, however obtained at a different location in relation to the at least one metal foundry machine. The type of environmental disturbance is determined by the physical , na--5 ture of the eiMronmenial disturbance... For example one type of environmental disturbance may he dust, i.e. particles, white another type of environmental disturba ce may be noise, i.e. sound waves. Other types Include heat, i.e. energy and consumption of a resource.

Where more than one instructions are obtained based on more than one ^■ environmentalQ. disturbances for operating the at least ohe metal foundry machine, one of the more than one Instructions may, while being configured to cause a decrease of one of the more than one environmental disturbances, at the same time cause an increase in. another of the more than one environmental disturbance; n this case the method as defined in claim 1 may further comprise the step of obtaining an order of priority of the mere than one environmental5 disturbances, and based on this order of priority perform the further step of modifying one of the more than one instructions, such that the one of the more than one instructions that causes the decrease of the one of the ore han one environmental disturbances having the tower priority is rendered ineffective before using It to operate in© at feast one metal foundr machine, or vice versa.

0

Alternatively the method as defined in claim 1 may additionally comprise the step of determining whether or not the more than one■environmental .disturbances and the mors than one instruction configured to cause a decrease of these environmental disturbances, are such as io risk running counter to each other as described above, and further the step of5 obtaining an order of priority of the mom than one environmental disturbances. Generally a metal fou n dry oomp rises a first pluralit of metal foundry machines. Accordingly claim 2 defines preferred embodiment: of the method according to the first aspect of the present invention. THe embodiment according to claim 2 is advantageous as In this embodiment the method according to claims 1 , LeJhe steps Mir-is are performed for each of the first plurality of metal foundry machines,, thus resulting in a large overall decrease of the at least one environmental disturbances for a large lowering of the environmental, impact: of the operation of the metal foundry.

Each of the first plurality of metal foundry machines are preferably different from each other.

Generally a metal foundry comprises a first plurality of metal, foundry machines producing a second plurality of second environmental disturbances, Accordingly claim 3 defines a _: preferred embodiment of the method according to the first aspect of the present invention. The embodiment according to claim 3 1s advantageous as in this embodiment the method according to claims 1 i.e. the steps l-iii Is are performed for each of the first plurality of metal foundry machines and for each of the second pluralit of environmental disturbances, thus resulting in a large overall decrease of the second : pi uraiity of environmental disturbances for a large lowering of the en ironmental impact of the operation of the metal foundry.

The second plurality is preferably greater tha the-ftrs plurality,, in other ords ai feast one of the first plurality of metal foundry machines preferably produce i o- or more environ- menial disturbances.

The third plurality is preferably greater than the first plurality- but may also be less than the first plurality. In the latter case the environmental disturbances produced by more than one of the firs plurality of metal foundry machines may be measured collectively in a single measurement for these metal foundry machines.

The fourth plurality may be equal to or greater than the first plurality; in othe.rwords-.each of the first; plurality of metal foundry machines may be operated using one of the fourth plurality of instructions.

Claim 4 defines different advantageous embodiments at ^' the method, according to the first aspect of the present-invention as regards the step of obtaining: the at least, one Instruction. Using at least one threshold value Is an easy method of lowering the environmental Impact of the operation of the metal foundry as a threshold valu is easily set Depending: on the environmental disturbance measured, the at least one threshold value may be an upper or lower threshold alue. The at least one threshold value should be selected so as to define the level where the environmental disturbance results In an environment-thai is harmful to the workers or the operators of the metal foundry, or where the environmental disturbance damages the environment or results In defective castings.

The at least one threshold value may be set manually by a; worker or an operator of the metal foundry and/or the metal foundry machine. The at least one threshold value may also be set automatically; for example by being calculated according to some algorithm:, For example: the at least one threshold value could be set to the product of a factor and the mean value of the at least one measurements of the at least one environmental disturbance during the previous month, week or day, thus the at least one threshold could: be automatically updated to for example 110% f the mean value of the at least one measurements of the at least one environmental disturbance during the previous month. The. at least one threshold value mav alternatively be set such that an est mation of the integral of the at least one measurements of the: environmental disturbance over certain future time period, results in totai euvironmental disturbance below a certain amount. The threshold . value for the measurement of a first environmental disturbance may additionally be influenced by th threshold value of a second environmental disturbance either where there is a synergic effect of the first and second environ mental disturbance, for example heat and noise having a synergistic effect on worker environment or where: the first or second, environmental, distur- bance ha a higher priority. I.e. is more important _. to keep within th acceptable range defined fey the threshold value related to the measurement: of the first environmental disturbance, than it Is to keep within t e acceptable range defined by the threshold value related to the measurement of the second environmental disturbance.

The at least one threshold value may further be set according to official guidelines or laws. For example, as regards air pollution of lead (Pb) the mandated threshold value in air Is 50 Ug lead/m ³ in the example with lead further, higher thresholds are set by official guide lines or laws, these higher thresholds being 50-75 pg: lead m ⁵ and »75 pg iead/m ³ and requiring the use of personal safety equipment, and checking the health of the workers respectively. Manganese ( h), which Is an additive: used in metal foundrie for casting steel and special steels, has an official threshold level of 0,1 mg m ^s air for manganese in breathable form and a threshold level of 0,2 mg ^: /m ³ air for manganese as smoke, dust, or powder. Manganese Is * O very toxic and can oause serious and irreparable damage to th brain and e nervous system.

The at least one comparison result may be a valu indicating how much the a least one measurement differs from the at least one threshold value,, or it m be Boolean value indicating whethe or not the: at least one measurement is within the range defined by lhe at least one threshold value and a measurement when the metal foundry is slo operated. Where the at least one measurement is a direct measurement the at least one threshold value is typically an upper threshold value whereas when the at least one measuremen is an indirect measyrementlhe at. least :.ors@ threshold value is typically a lower threshold value.

Looking up the at least one instruction in a look up table is fast: hile using a function: operating on tfre-at least one comparison result or the at least one measurement provides more different instructions for a more exact and minute operatio of the at least one metal foundry machine.

The look-up table may comprise measurements values wher each measurement value is correlated to. a corresponding instruction. The insirucfiors corresponding to a certain mea _. s- urement value may have been determined empirically,, by testing different instructions for a certain measurement value of the environmental disturbance; and Including In the look up fable the Instruction lowering the environmental disturbance the most The. inst uction correlated to a certain measurerneni value- may alternatively be determined analytically by considering how different instructions would affect the environmental .disturbance.

Additionally the instruction corresponding to a certain measurement value may be set by past experience, L- . by considering whether a certain Instruction, such as for example increasing the flow of water to the shake out machine, was executed in the past or previous hour or day of operation of the metal foundry for the measurement that has been obtained, Thus, where: an operator or worker of the metal foundry provides an ^' instruction- for operating the at least one metal foundr machine, the instruction, corresponding to the measurement value at the time that the operator or worker .provided, the Instruction,. thi instruction corresponding to the measurement value in the look up fable may be. set to the instruction provided by the operator or worker.

- ^■ ·?::,- Further, . nstruc ions to the look up table for a certain measurement valu may be set to the instructions prevailing at the cessation of operation of the metal foundry, for that certain measurement value, such that next time the operation of the metaf foundry commences again if starts with the instructions prevailing; at the cessation of operation of the metal foundry..

Obtaining th instruction from a worker or operator of the metal foundry provides for handling exceptional environmental disturbance outside the allowed input values for the look u table and the function. The instruction: obtained by the operator or worker, together with the measurement value which prompted th instruction from the worker or operator, ma then : be stored in the look up fable for future use.

Ths look up table ma comprise mor than one threshold ^' for each measurement value. Thus, at a first fhroshoid corresponding to a comparison result which shows a small deviation of te. measurement value a fifst inslruetion may be obtained. This first instruction may result in a small change of operation of the metal foundry. At a second threshold, corresponding to a comparison result which shows a large deviation of the measurement value a second instruction i obtained resulting I large change in operation of the metal foundry machine. The second instruction may for example be _; obtained from the operator or worker of the metal foundry. in some embodiments of the method according to the first aspect of the present invention the method further comprises the steps of;

^• Obtaining -information .a oui the operation of the metai foundry, and using the information when obtaining the at. least one instruction.

The Information may for example comprise the intended production rate of the metal foundry, the type of mould used in the metal foundry, the number of moulds: On the mould conveyor, the weight of each mould,- whether or -not the moulding machine and the mould conveyor are running, etc.

This ^fomation may he used for obtaining instructions which proaetively operate the metal foundry machines, As an example the measurement value for air pollution / dust at the shake out machine may reflects low value of air pollution during a. pause in operation. To lo erthe: environmental impact the method attempts to -further lower the water consumption. As- he operation Is paused no moulds are delivered to the shake out machine, there- fore no dust ls created by the shake out machine whic allows- fh® water consumption to eventually be shut off completely. Using the information, In this case information that the operation has now commenced again for example by obtaining information on moulds being produced by the moulding machine, the sup ly of water to the shake Out machine ma be activated: proacf ive!y so that there Is already water being _, supplied to the shake out machine when the first mould is deli e ed thereto after operations has commenced again. This may avoid suddenly releasing dos from the first mould, and a corresponding pea kin air pollution before the air pollution has been detected and the suppl of water to the shak out machine resumed.

The information may be obtained from a controlling com uter and/or from an operations sensor associated with the respective metal foundry machin s.

The information: may be used as an additional input to the at least one measurement in-op der to modulate the obtained instruction, or may be used to obtain a different instruction than the one obtained solely on the basis of the measurement.

The information may also be used to set the instructions in the look up table or for setting thresholds. This may result in a mere proactive operation of the metal foundry

This ipfermatjon may for example comprise- information, such as _. the current speed of a metal foundry machine, which is derivable from measurement values or currently executed instructions for other metal foundry machines. Thus this information may for example be obtained from the moulding machine, by analysing the instruction currently used to operate the moulding machine, This information ma for example comprise the number of moulds formed per hour. This information may then be used to _: proactivel set in the look Up table ari instruction for the shake out machine, this instruction being known from past experience to he suitable for keeping air pollution within the thresholds, Thus the look up table ma comprise more than one input parameter fo each instruction. To exemplif the look up table ma comprise a first inpu for the measurement value of the environmental disturbance-,- in this ease dust/air pollution caused by the shake out machine. The ^' took up table ma further comprise a second input for th number of moulds; per hour thai is being made, the numb r of moulds: per hour being: an example of the information about the operation of the metal foundry: These firsthand second inputs ma foe prioritized for example such that during the first hour of operation the. shake out machine may be- op- erated using an instruction that is correlated to the present number of moulds per hour, After -the first hour however the shake out machine may be operated using an: instruction that is correlated to the measurement value of the .air pollution at the shake out machine, in this way a better and more robus operation of the metal foundry machines is achieved.

Information about the operatio of the metal foundry may be used to obtain- instructions of rneta i. foundry machines such as compressors for pressurized ait., in this case the information may comprise the l requirement of pressurized air for the metal foundry machine in the metal foundry. The information ma further comprise pressure measurements for the reservoir of pressurized air of the compressor.

As regards air pollution the Information of when production is to be started: may be used to obtain an instruction for starting a ventilation or air, fitter system prior to actual eommenee-- raent of operatio of the metai foundry..

Further Information about whether or not a moulding machine is running ma be used to obtain an instruction for stopping- a metai foundry machine such as a shake out machine or mould conveyor if no moulds are produced by the moulding machine, thereby saving money and resources: In this case !he information about the operation of the metal: foundry may be obfainedjrorn the controlling computer directly or by operations sensors connected to the mouiding machine.

Likewise -information about the operation of the metal foundry ma be used to control lighting of the- metal foundry fo -avoiding lighting up the metal foundry if there is no operation of the metal foundry. here long time production goals are known and comprised by the information-, this nfor- mation may be used to obtain instructions to the at least -one metai foundry machine for causing the at least one metal foundry machine to operate at the lowest speed still allowing the required production goal to be achieved.

If the Information, or the at least one measurement, comprises an- air temperature this air temperature may be used to. obtain an Instruction for pre-heatlhg an air extraction duct so that hot air from the metal foundry- does not condense, in. the extraction duct causing sand and dust to aggregate n-the extraction duct. Such aggregations are difficult to remove, thus the prevention of the formation -of such aggregates is desired. 18

Furt er, information about the operation of the me al foundry may be used W reduce noise by operating the moulding machine and mould conveyor at a tower speed.

Information about th operation of the metal .foundry m y also be collected from operations sensors such as vibration sensors which may be used to warn of m mi nent failure, as diagnosed by vibrations, of the at least one metal foundry machine. This increases the longevity of tie metai foundry machi e: Aiso oil quality sensors may be used to measure and analyze fabricating or hydraulic όϊί in order to Operate the metal foundry machines so as to prevent fail lire thereof.

Other operations sensors include Image sensors for obtaining information on mould -quality, Hyperspecfra imaging using hypsrspeetra! sensors may be used to measure air pollution caused by dust nd or chemicals.

The embodiment according to claim δ Is advantageous as in this embodiment the operation of the metal foundr is optimised, so that the total amount of environmental disturbances is minimized. The first sum artd: the second sum may be formed by multiplying eaeh of the respective measurements of the environmental disturbances with a constant fo obtaining a common unit for the value of the sums. This unit may for example be cost or energy. The c mmon unit ma he dsmeneioniess by dividing each .measurement with _: a base measurement, For example a noise level In dB ma foe divided by a base: measurement: of 100 dB. Similarly a power measurement in Watt may be divided by a base measurement of 1000 Watt. The value of the base measurement for each meas.urem.ent; may be used to weight the impact that each environmental disturbance should: have on the sum of environmental disturbance. Thus if the value of the base measurement is small the corresponding environmental disturbance will contribute ora to the sum of environmental disturbances ¾nd vice versa.

To make the sum of environmental disturbances a cost the value of each base measurement should be set to reflect the cost: associated with operating the metal foundry at the amount of corresponding environmental disturbance that Is measured.. For example, as regards power, the value of the base measurement Is the cost df each watt hour of power tha is consumed, likewise the value of the base measurement for water usage is the cost per n * of consumed water. Waste water that must be released to a municipal waste wafer treatment plant similarly entails a cost par m ³ , Filters used ^' in air filtration devices, for filtering polluted air, also entails a cost per rr of air filtered and the amount of pollution in the air.

Instead of haying a single constant base ^■■ measurement for each e vironmental disturbance when computing the first sum, a base function may be set for each environmental disturbance. The base function fakes as input the measurement value of the corresponding environmental disturbance and returns a: dime sionles number or a cost. In fact, a base measurement as described above represents a simple base function, A more cdmpiicaied base function may comprise a quadratic, polynomial, linear, exponential or other relationship between the --measurement and the cost. The base function may further be discontinuous such as for example in the case of a base function for nois n whic noise levels below a first threshold entails no cost noise levels above the first-threshold and below a second ^■ threshold: result in a .moderate cost based on; the cost of providing workers with hearing protection,, and noise above the second threshold entail a high cost based on needing to discontinue operation of the metal foundry, with concomitan loss, of earnings, due to violating tews o worker environ m n!,

A further example of a discontinuous base function is the cost for eiectricai power where the, cost per wail hour may be different for different times of the day and; night Such a differentiated cost of electrical power will influence the opera!iQn of the metal foundry. One example related to minimizing air pollution com prises, increasing ower to fans in a ventilation: unit during th night when electrical power Is cheap, thereby allowing decreasing the water supply to the shake out machine and thereby reducing the cost of water _. .. At da time, when eiectricai power is expensive,, the electrical: power to the fans is decreased and the supply of wafer to the shake out machine is Increased. In both cases, night operation ^; and day opera* lion, the air pollution is minimfeeci whiie taking advantage of the lower cost of electrical power at: nig t

Step vfmay further comprise obtaining at least one previous ^' instruction, -the previous instruction being associated with the status of the at least one metal foundr machine at which the at least one measurements are obtained, storing the at least, one previous Instruction, and provided the estimation of the second sum is large than the first sura causing the at least one instruction obtained in step is to be identical to the at least one previous instruction before performing step ill. This ensures that if the. estimation of ins second sum is larger than the first sum the at ieast one previous instruction is used to operate the at least one metal foundry machine.

The -estimation ma be o tained tef modelling the at feast one metal foundry machine usmg an empirical or analytical or logical correlation between the measurement of the at least one environmental disturbance and: that at leas one instruction.

Ah empirical correlation between the measurement of the at least one environmental disturbance and the at least one instruction may for example be determined empirically by running the metal foundry machines using different instructions, in the case of a mould conveyor at differeni speeds, and for each instruction measuring and storing the values of the environmental disturbances. In the case of a mould conveyo the mould conveyor would be run at differen speeds and the noise produced at each speed would be measured and stored. The measurements may be used to construct a look up table, or alternatively may serve as data for making a linear or other regression suitable for use in a function taking as input an instruction and provi ing, as- oyjpui the-.amo.unt of en^ronmentaldisfurbance produced when operating a metal foundry machine using the instruction,

A case of an analytical or logical correlation between the measurement of the at least one environmental disturbance and the at least one Instruction may for example be found for the water consumption in the shake out machine as in this case the instruction to increase the water supply with 50 % logically results in an increase of water consumption by 50%,

Thus, once the at least one instruction has been obtained this at least one instruction is used in the above mentioned .look: up table, regression or function to obtain a corresponding measurement of the at least one environmental disturbance. The second sum may then be calculated by obtaining the cost er amount of the environmental disturbance using the base measurement or base function mentioned above.

Claim 6 defines different environmental disturbances. Air pollution may be air pollution due to dust, sand fines, mineral fines, chemical vapours, metal droplets, metal vapours etc. Heat ma comprise hot air. hot steam, and hot fluids. Noise may comprise sound, vibrations etc. C©2. emissions may comprise Ct¾ emissions occurring directly from the metal foundry machine, andfer CD¾ emissions occurring -indirectly through the power usage of the metal foundry machine. Energy consumpiion comprises the energy consumed by the metai- oun- dry machine. Water consumption comprises the water consumed, by the metal foundry ma~ 18 chine. Production waste comprises waste m the form of green sand which cannot be used, defective castings which must be discarded or molten down, surplus metal from the pouring of olten metal, etc. Further environmentai distur anees: include drafts and air jets, release of pressured air etc from the metal foundry machine.

Claim 7 defines different Instructions. Controlling the speed of the metal foundry machine may comprise lowering the speed which, dependent on the metal foundry machine, reduces noise, air pollution, energy consumption, water consumption, and/or C<¾. emissions. Controlling the supply of water to the metal foundry machine may compris increasing the water flow causing a reductio in formation of dust, thus reducing air pollution. Controlling lubrication of the metal foundry machin may comprise adding lubrication to the metal foundry machine causing a reduction in, power consumption. Controlling means for counteracting the environmental: disturbance may comprise controlling fans, fresh air inlets, filters, air cleaners etc, to reduce air pollution, controlling an air conditioner to reduce heat, etc _*

Claim & defines a preferred embodiment of the method according to present invention. The heat exchanger not only reduces heat by absorbing it, it also makes the heat available for reusing fo heating other parts of the metal foundry or for generating electricity, Preferably the heat exchanger is mounted over a metal foundry machine such as a moulding conveyor, melting furnace, pouring furnace or moulding line to absorb the heat from the molten metal in the moulds.

Further metal foundry machine above of in relation to which the heat exchanger may be placed for .absorbing heat includes heated and unheated pouring units such as easting ta- dies.

Thus the present invention also provide that energy may foe reused from a moulding conveyor, meitsng furnace, pouring furnace, or. moulding _, fine by absorbing heat from the molten metal In the moulds and using this heat for heating or electricity generation,, via a suitable turbine, while the absorption; of the heat also provides a better environment, l.e, less hot, for the workers or operators of the metal foundry.

Preferably tire energy absorbed by the heat exchanger- is used to power the metal foundry machines and/or the ventilation machines whioh provide-veniilation forme metal foundry. in preferred embodiment of the method according to the first aspect of the present Invention the measurement and/or the com pariso result may be ispla ed .-on. the metal to urtdry machine, on a printout or computer screen, on a _. central printer or computer screen, or re~ moieiy on a computer, PDA, or Smartphobe. Th s is advantageous as it allows the worker or operator of the metal foundry to be informed of the environment and the measurements of the environmental disturbances.

At least one of the above objects, or at least one of any of the further objects whlsh will be evident fro n the belo description, are according to ύ second aspect of the present invention achieved by the system according to clalra 9,

The system according to the second aspect of the present invention ^■ performs the method according to- the first aspect of the present invention.

Preferably the at least one sensor is place in the vicinity of ihe at least one- metal foundry machine; however It may also be placed withi the a least one etal -foundry machine, associated with a resource required by the a least: one: metal foundry machine, in the. metai foundry, or outside the metai foundry.

The at least one senso may be an air quality sensor such as a CQ ₂ sensor, and 0 ₂ sensor, an 0 ₃ sensor, adust content sensor, a smoke sensor, -a ga sensor, a relative humidity sensor, an airflow sensor.

The at feast one sensor may furthe comprise a beat sensor such as a, temperature sensor or a radiant heat (IE) sensor.

The at least one sensor may further comprise a. flow sensor such as a water flow or usage sensor, a green sand flow or usage sensor, etc.

The at least one sensor may further comprise a power sensor (measuring electrical power used by a metai foundry machine).

The at least one sensor may comprise a microphone or sound meter to measure noise. Further the sensor may be a vibration sensor to measure vibrations.. The at teas* one sensor may e a pressure transducer or strain gauge for measuring pressures and forces present between parte of the metal foundry machines, and/or between moulds and he metal foundry machines.

The at f east one sensor may foe a vision system for -obtaining and processing images of metal foundry machines, details of metal foundry machines, moulds, castings, sand etc. The at least one sensor may further comprise .an -electric- field sensor or a magnetic field sensor.

The at least one sensor may be a scale for weighing production scrap or green sand waste. The at feast one sensor may additionall be comprise- a- PDA, computer or Smartphone used by a worker to manually provide measurement for example the subjective air quality experienced by the workers or operators or the amount of fettling, i.e. manual treatment of the castings such as cutting, sandblasting, and polishing.

The at feast one sensor may he connected to the centra! computer either wireiessly or by wire.

The at. least one sensor is con igured to obtain at least one measurement of the at least one environmental disturbance. This means that he. at least one sensor Is suitable for obtaining at least one measurement of the at least one environmental disturbance.

The. controlling comput r is configured, to b a the at least one measurement and the at least one instruction. This means thatihe controlling computer is suitabl far obtaining the at least one measurement and the at least one instruction.

The controlling computer may be a server or personal computer running a program causing the computer to be configured for the tasks defined in claim 9. The central computer may host a server or site for displaying and making available the measurement and/or comparison result to local or remote workers or operators of the metal foundry. The controlling computer may comprise a screen for displaying the measurement and of the comparison result to .the: workers or operators of the metal foundry.

The controlling computer is further preferably configured to, or suitable for, communicating ih¾ at least one instruction to the controlling device. * The at bast one controlling device may eompnse any device for operating the at leas one metal foundry machine using the at least one instruction. Examples include an electronicall or pneumatically actuated valve, an electronic speed controller for controiling the speed of a metal foundr machine, an electronicall controlled lubrication pump, an electronic relay for activating an air-condition of air Gleaning device, etc.

The controlling computer may be configured for obtaining the at least one instruction by being configured to perform the method according to claim 4 as defined irrclairn 4 and described in relation to claim 4 above.

In come embodiments the controlling computer is further configured for obtaining information about the operation of the metal foundry, and using the information when obtaining the at least one instruction.

The controlling computer may for example he configured to store or access the intended _: production rate of the metal foundry, the type of mould used in the metal foundry, the number of moulds on the mould conveyor, the weight of each mould, whether or not the moulding machine and the mould con e or are running:, etc.

In some cases the system according to the second aspect of the present invention may comprise at; least one operations sensor configured for obtaining at teas! part of the information. The operations sensor may for exam le comprise a motion detector, for detecting motion of the mould conveyor, a weight sensor for determining the weight of a mould, an image sensor for detecting: workers in the metal foundry. The operations sensor may fee associated with a metal foundry machine or alternativel the controlling computer may be configured fo obtaining the information directl from: a metal foundr machine.

The .controlling computer may be configured to use the information for as an additional ^' input to the at feast one measurement in order to modulate the obtained instruction, in some cases the controlling computer may be configured to prevent execution of the obtained instruction -until t e information shows that a critehum:, for example that the production is ruh- ning, is fulfilled.

Further -operations sensors include vibration sensors, oil quality sensors, Image sensors, humidity sensors and hyperspecirai sensors. ' A preferred embodiment of the system according to the present invention is defined in claim W. Generally mefai foundries, comprises a first plurality of metal foundry machines producing a second plurality of environrnentai disturbances, thus the embodiments according to claim 10 is ad a tageous as it decreases the fetal amount of environmental disturbances.

The fifth plurality may be greater than the second plurality «here more- t an one sensors are configured for obtaining a rneasurement of the sarsie environmental disturbance.

The sixth plurality may he less: than the fourth plurality where at least one of the controlling device can handle more than one instruction.

Ih correspondence to the method according to claim 1 the controlling computer may be configured to obtain an order of priority for the environmental _, dis pr snoes for prioritizing the instructions if there a re more t an one environmental dist urbances and more than one Instruct Ions,

The preferred embodiment of the system according to the present invention defined in claim 11 minimizes the environmental impact

The summing module, the modelling module, and the control module may be jfnpiemented In hardware or software. The controlling computer is preferably configured to perform the method according to claim 5 as defined in claim 5 and described in relation to claim 5 above.

The rnetaLfoundry as defined in claim 12 has a lower environmental impact.

The metal foundry as defined, in claim 13 has an even lower environmental Impact.

The system according to the second aspect of the present invention is especially suited for a. green sand metal foundry as defined in claim 14.

The preferred embodiment of the metal, foundry as defined In claim 1§ provides an even lower environmental impact by reusing heat from the metal foundry machines. The means fo converting the heat absorbed by the heat exchanger ma Include a thermocouple, a steam turbine, a heat pump etc. The energy may be heat energy or electric energy, etc.

The heat exchanger as defined in clai 15 rtsay be used in a foundry as defined in claim 1 S without the system according to the second aspect of the present invention.

Thus: a metal foundry comprising any of a moulding; conveyor,.. a pouring unit, a: melting furnace, a pouring furnace- er a moulding One, may comprise a heat.. xc anger placed so as to absorb heat from any of said moul ing conveyer, pouring unit, m sling furnace, pouring furnace or moulding line, arid the metal foundry: may further comprise means for converting the heat absorbed by the heat exchanger to energy for operating the metal foundry and the metal fouh dry machines in the metai foundry.

The invention and its many advantages will fee described in ^' more detail elow with reference to the accompanying schematic drawings, which for the purpose of illustration sho some non-limiting embodiments, and in which.:

Fig. 1 shows am ef.a! foundr comprising a system according; to the second aspect of the present invention for operating the metal foundry in accordance with the method according to the first aspect, of the present invention; pig. 2 shows the system according to the second aspect of the present invention and its connection to an exemplary -metai -foundry -machine, and

Fig. 3 shows flow diagrams of embodiments of the method according to the first aspect of the present. invention. in the below description, a superscript, roman numeral added to a reference number indicates thatthe element referred to has the sam or similar function as the element designated the non-superscripted reference number;, however, differing in structure.

When further embodiments of the ^' invention are shown in the figures, the elements which are e ; in relation to earlier shown embodiments, have new reference numbers, while elements ^' previously shown are referenced as stated above. Elements which are identical in the different embodiments have been given the same reference numerals and no further explanation of thes elements will be given.

Fig. 1 shows metal foundry, in its entirety designated the reference numera 2. The metal foundry 2 comprises a plurality off metal foundry machines as iii now be described. A first metal foundry machine is a green sand storing and providing machine 10 winch comprises a silo 12 for holding green sand, an elevato 14 for receiving roused sand and transporting it to the .silo 12, a screen 16 for conditioning and sorting sand, a sand mixer 18 fo mixing sand, and a. sand measurement device 20 for providing a controlled flow of green sa d to convey or .22.

Green sand is delivered from the green: sand storing and providing machine 10 Via conveyor 22 to a second metal foundry machine which is vertical green sand moulding machine 30. Vertical green sand rnouiding machine 30 receives the green sand with a hopper or sand supply unit 32 and form the green sands: into mould by pressing a shot of green, sand between a pair of pattern plates (not shown}. Where needed for forming void in the casting a core (not shown) may be attached to one or both sides of the green, sand mould 34 exiting: from the vertical green sand moulding machine 30. The core is produced from green sand or other materials in a third metal foundry machine which is a core shooter machine 40,

After the g een sand mould 34 has exited the vertical green sand moulding machine 30 it is passed to a growing Sine of sand moulds ea ied by a fourth metal foundry machine which is a mould conveyor 50.. Two green sand moulds 34, when placed .together, form a moulding cavity between them for receiving molten metal.

Molten metal is . then poured by a pouring unit such as a casting ladl (not shown) into the mould cavities formed by the array of green sand moulds 34 present on the mould conveyor 50.

During the- pouring ashas from burnt off components of the green sand mould 34 may escape info the air and thus these ashes represent air pollution produced when running the mould conveyor 50 and/or the pouring unit.

A heat exchanger 52 is placed above the conveyor 50 for receiving, some of the heat emitted by the molten metal in the green sand moulds 34. The heat exchanger 52 may Include an elongated shroud for collecting hot air rising from the green sand moulds 34 on the con- vayor 50 and tubing i p!aeed within the shroud, through which tubing a neat exchanger fluid is passed o as to b heated by the hot air. Th heated fluid may be used to drive a turbine for converting the heat of the hot air to electrical energy using a generator connected to _. the turbine,. Alternatively the heated flui may be used to heat other pads of the metal foundry or for providing steam for the rn et ! foundry machines. The electrical energy can also be used to power the met l found y machines. ier the molten metal has solidified the green sand: mould 34 Is deposited Into a fifli rneia! foundry machine which is a shake out machine 60, The shake but machine 60 causes the green.: sand moulds 34 to separate and break up so that the green sand moulds 34 are removed from the eastings. Water is added through spray heads, one of which is designated the referenc numeral 62.

The shake out machine 80 then passes the casings and green sand moulds 32 to a sixth metal foundry machine which is a sand cooler 70 comprising a drum 72 through which the castings and green sand mouids 34 are led /Water is added to the drum 72 to- further remove the green sand from the castings and to further break down, and cool the green sand. The water further humidifies the sand and reduces air pollution in the form of sand and dust produced when running the sand copier 70. The sand cooler 70 also cools the eastings. The sand cooler 70 further includes a disintegrator for further breaking down the sand into individual grains before the green sand is passed on to a seventh metal foundry machine which is a third conveyor 80 which conveys the sand baekto the green sand storing and providing machine 10 for reuse. The third: conveyor 80 further comprises a magnetic separator .82 for removing any iron or sfeei particles present in the green sa _. ncb

After passing through the sand coo er 70 the castings are passed onto a eighth mefaf foun-- dry machine which is a casting cleaning and treating machine 80 in which the eastings are further cleaned, by removing any sand residue, cooled, and collected for further processing,

.As regards environmental disturbances the green sand storing -and- providing machine. 10, _. when used in the operatton of the metal foundry 2, produces dust and noise, thus air pollution and _. rioise.are environmental disturbances for this machine. Further environmental disturbances related to the green sand: storing and providing machine 10 are water usage and power usage. 2?

Vertical green sand moulding machine 30 and cere shooter machine 40. when used in the operation of the metal foundry 2, also produce dust and noise, thus air pollution and noise are environmental disturbances for these machines. Further these machine require power, therefore power usage is- also an environmental disturbance for these machines.

Mould conveyor 50:, when used in the operation of the metal foundry 2, requires: power and creates noise , thus power usage and noise are environmental dist urbances for t his ma -- chine. Further the heat of the molten metal In the green sand moulds 34 causes ^' large amount of heat to be emitted by the green moulds 34 on the mould conveyor 50, thus heat is an e n vi ron me nta J : disturba nee related to f hi s machine ,

Shake out machine 80 generates, when used in the operation of the metal foundry 2, both dust and noise, thus air pollution and noise are environmental disturbances for this machine, Fuffher this machine requires power to run and water to limit dust making power usage and wafer consumption environmental disturbances for this machine,

Sand cooler 70 generates, when Used in the operation of the metal foundry 2, both dust and noise, thus air pollution and nois are: ^■ environmental disturbances tor this machine. To cool the green sand and the eastings, and to limit dust formation, water is used by the sand cooler 70, thus; water Usage is an environmental parameter of this machine. Also power is used by this machine, thus power usage is also an environmental disturbance of this machine:

The third conveyor 80 requires power to r n and generates both dust and noise, thu power usage, air pollution: and noise are environmental disturbances for this machine.

Casting cleaning and treating machine 90: requires power to run aM generates noise, thus power usage and noise are environmental disturbances for this machine..

Metal foundry 1.0 further comprises a system., inits entirety designated the reference numeral 100 for operating the metal foundry. System 100 comprises a controlling computer 110, a plurality of environmental disturbance sensors (not shown in fig 1), and a plurality of operating devices or controlling devices (not shown in fig 1). The environmental disturbance sensors are distributed throughout the metal foundry 10, and are preferably placed in the vicinity of the metal foundry machines. The controlling computer 1 10 includes a display! 12, the Use of which will be described In relation. to fig. 2 and 3. The .controlling com iler 110 may further communicate via network 140 with a Sroariphone 150 as will be described further ^' below.

The vertical green sand moulding machine 30 shown in fig. 1 may be substituted by a horizontal itaskless matchplat machine.

The: cer shooter machine 40 may be any of a Co!d-Bex, Hoi-Box, Droning, SC½ or inorganic -core shooter machine.

Fig. 2 shows the system 100 in relation an exemplary metal foundry machine, in this ease shake out machine 60. An environmental disturbance sensor which is an air quality sensor 120 is placed in the vicinity of the shake out ^' machine- 80 and connected, to the controlling: cornpyief 110 via wire or ir Sessly, The air quality sensor 120 is placed so as to measure the air quality, and accordingly any air pollution,, caused by the shake out machine 60,

The system 100 further comprises a controlling device, connected by wire or wireiessiy to the controlling computer 10, for .controlling the operatio of the shake out machine 60. in fig, 2 this controlling: device is embodied by a controllable valve 130 governing the supply of water to the shake out: machine 60..

Further-environmental disturbance sensors comprised by the system 100 include noise sensor 120', heat sensor 1 0", energy consumption .sensor- l^o"', water consumption sensor 120 ^IV , and production waste sensor 120 ^y .

The controlling computer 110 ma report the measurement and/or the comparison result via the network 140 to the Smart hone ^' 50. as described below.

Although in fig. 2 the respective sensors, including inter alia air qualify sensor 120, are placed in the vicinity of the metal foundry machine, the sensors may alternatively _, be placed apart from the metal foundry machines. In this case metal foundry machines producing a certain -environmental disturbance may be jointly operated by the controlling computer 110,

The -controlling computer 110 may include a control Interface for setting threshold values and functions for the respective environmental dlsturhahces. The controlling computer may additionally include a server for hosting a control interface for displaying measurem nts., threshold values,. functions, and or instructions and for receiving commands:- for setting the threshold lu s, modifying of. etting the functions, or issuing instructions via the network 140., the network 140 may - comprise a LAN, vVtAN, or WAN network such, as the Internet,

The controlling computer 110 comprises a dat storage for continually storing measurements, current threshold values and functions and/or instructions in a log file. The controlling ^' computer preferably provides the log file for display on the display 112 or fcn the control interface.

The controlling computer 110 may be programmed to display a 2D or 3D picture Of the metal foundry and to display the respective measurements and threshold values adjacent the corresponding metal fou dry machine in the picture.

The control computer 1 10 is preferably, as shown in fig. 1 , placed: in the metal foundry 2, However, the controlling computer 1 10 may alternatively ibe placed remotely from the metal foundry- 2. in the latter case the controlling computer may be placed in a building adjacent to the metal foundry 2, -or even further away provided; that suitable communication links, wired or wireless, interconnect the controlling computer 110 with the air quality sensor 120 and the controllable valv 0,

If desired the controlling computer 110 may be programmed to provide an alarm, either b displaying a visual cue on the display 1 12, emitting a sound Using a speaker (not shown) or by email and/or S S, to a worker or operator of the metal foundry 2 to alert the worker of operator of the metal foundry 2 when a mea urement^eviafes, such as being too . high or loo low from the threshold value.

Fig. 3A show a flow diagram 200 of an embodiment of the method performed by the system 100, The steps are described beiov with reference to the system 100 sho n in fig. 2. in step 210 the controlling computer 110 obtains a measurement from the air qualify- sensor 120. In step 220 this measurement is compared to a threshold value corresponding to the ma¾mum allowable air pollution, i.e.. amount of sand dust ih the air. If the amount of air pollution is above the threshold value the method obtains an instruction in step 230. which Instruction is then communicated to the controllable valve 130 for increasing the amount of water so as to decrease du formation in the shake out machine 60. In this way the air qi¾a¾ is maintained suitafefyf F-ihe workers;,- ^■ : ^■ -\ A status report including the measurement and/or the comparison result is sent to the workers using network 140 and ..Smartphone I SO, or by display on the screen 112 in step 240, in case th amount of air pollution is below the threshold value the method may either go directly b ck to step 2.10, or alternatively go to step 230 but generate an Instruction which causes the controllable valve 130 to remain as it is.

If the system 1 Q0 includes a water usage sensor placed so as to measure the water usage of the shake out machine 80, the method 200 ma further require steps for measurement, comparing, and operating based on the water usage. In this case the above described operation of the controllable valve 130, to increase wate flow to reduce dust formation, may result In the- waiter usage read by the aon roltlng computer 1 0 using the. water usage sensor Increasing past the threshold value for the water usage. In this case the controlling computer will obtain an instruction and communicate it to the controllable valve 130 to re- duce the water consumption, The controlling -computer 1 10 is preferably programmed to prioritize the environmental disturbances so that these related to worker environment, and ultimately worker health, are prioritised. Thus the controlling compute 1 10 is preferably programmed to keep the water usage below the threshold value for water usage only if the air quality measurement is elow -the. hreshold value for air quality. The method 200 ma therefore comprise steps for measurement a -plurality of environmental disturbances, comparing the measurements to a plurality- of threshold alues, generating a- plurality of instructions prioritized according to the priority of the environmental disturbance corresponding to the Instruction, and operating the shake out machine 60 only using the highest prioritized instructions for each type of instruction.

The controlling computer 110 may alternatively be programmed to. modify instructions associated enyironmentai disturbances having lower priorities so as to rerkier the ineffective.

Fi 3B s ows a flow diagram 200' similar to fig. 3A but in this embodiment power consump- tion of the mould conveyor 50 is measured in ste 210 ^s and compared: to the threshold value in step 220', If power consumption is too high an instruction for activating the means for providing lubrication to the moulding conveyor is obtained in step 230 ^' ' and i &4 to operate the moulding conveyor 50. A status report including the measurement and/or the comparison result is . sent to: the workers usi ng _: network 140 and Smartphon 150, or by display on the screen 1 12 in step 2 0 ^! . O !

Fig. 3C shews a flow diagram 200" similar io. % 3A having the same steps 210 and 220 but in: this embodiment if the air quality is top bad. a diagnostic alarm _, is serf ίύ an operator in step 250, by being sent to Smartphone 150, and the operato r manually, instructs the controlling computer 110 to increase water flow to the shake out machine 80 in: step 260. A status report -is finally sent to the controlling computer for storage in step 270.

Fig, 3d shows a flow diagram.2ΩΘ ^!Ι similar to. fig. 3A having fhe same step 2:10 but in this embodiment the instruction ¾ generated using a function operating on the Air quality, i.e. f(A) in step 220 ^y . In this case the instruction is used to adjust th water flow to the shakeoyt: machine 80, i step 230". f(A) may for exam le be water flow ^™ k * concentration of partieies in the air with k as a constant. Thus where the concentration of particles in the air increases the water flow will-also increase. Thus the instruction generated: by trie function is conf gured to cause a decrease of the concentration of particles in th air.

Fig. 3E shews a fe diagram 200 ^iv of an embodiment of the method performed by the system 1 GQ. in step 210 ^!i a third plurality of measurements of a second pluralit -of environmental disturbances produced by a first plurality of metal foundry machines are obtained using a fifth: of sensors such as sensors 120, 120 ¹ ,†2G ^M , 120™ ,120 ⁱ , 120 . in step 28:0 the sum of the third #iura .of :measurements-:ts determined represe-nting. ^' lhe total aniouni of environmental disturbance caused by. he metal-foundry 2, ^' In . determining the. sum suitable constants may be used to transform the measurements to a common; unit,, such as energy, cost, etc. The sum determined in step 280 is stored in system 100, for example In computer 1 10. in step 22:0 ^II! the second plurality of measurements is used; ta obtain a- fourth plurality. of instructions for reducing the ^■ environment l disturbances associated with the third plurality of measurements. These instructions are then used in step 290 i a. model of the metal foundry 2 to estimate the sum of the envirohmehtaf disturbances: that would be the result if the instructions obtained in step 220 ^;i! were to be used for operating- the. metal foundry machines. The principles of this model are described above in relation to claim 5, in step 300 this estimated sum is compared with the stored sum determined in step 280, and provided the estimated sum is less than the stored sum the instructions obtained Irs step 220 ^i!i are then used to operate the metal ^' foundry machines in step 23G ^m . if the estimated sum is i-ar~ gerthan. the stared sum. the method returns to step 220- ^il to try to obtain better Instructions, If a second; or third or fourth, etc., a set by the operator of the metal foundry 2, sefcoOnv structlons still do not result in an estimated sum that Is less than the stored, sum, theft _. he method e¾its and returns lo step 210" ^· .· The second , ihkd or fourth set constructions may be obtained by adding a random value to the .further plurality of instructions obtained in step 2.20"· to try to find a new minitr um sum of environmental disturbances.

The instructions in step 220 ^m may be■ obtained by using thresholds as described with reference to figs 3A B, by using operator input as described with reference to fig, 3G, or b a function as described with reference to fig:. 3D. Different measurements of the third plurality of measurements may be used: to obtain instrucstipns according to different methods, i.e. threshold, manual input, function.

As an alternative to that shown in fig, 3D steps 290 and 300 may be dispensed with and the sum stored in step 280 used merely fo reference or display to the workers or operators of the metal foundry 2.