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Traceability, Digital Twin and Data Analysis for Foundries

| Editor: Isabell Page

Together with new possibilities in blast simulation and new Wheelabrator aluminum machines, Norican will be demonstrating DISA's vision of zero-defect production at this year's GIFA. This goal is to be achieved with three new digitally controlled innovations.

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For the first time ever, foundries can gain full traceability with DISA’s new Trace and Guidance concept.
For the first time ever, foundries can gain full traceability with DISA’s new Trace and Guidance concept.
( Source: Norican Group )

Simulation of Blast Processes by Wheelabrator

Simulation of blast processes can speed up development of new machines and even inform the design process of the produced part – by testing buildability early on. Wheelabrator shows at GIFA what is possible in blast simulation, including how advanced simulation techniques save time and money during part and process design – a key advantage in today’s ever faster product development cycles.

Also on show will be the latest machine developments with extensions to and variations on existing ranges, including:

  • The SPH-2-3/8, a new compact blast machine designed specifically for aluminium applications.
  • The LBS 1000, a lighter version of the LBS mesh belt shot blast machine range.

Zero-Defect-Production by DISA

With the three components Trace and Guidance (TAG), the patent-pending Mould Accuracy Controller (MAC) and the Monitizer, Norican wants to pave the way for zero-defect production. “Finding the root cause of scrap can be extremely difficult,” says Per Larsen, Portfolio and Innovation Manager at DISA. “The total quality-related costs across foundries and casting users can represent up to 10% of the casting price.”

For the first time ever, foundries can gain full traceability with DISA’s new Trace and Guidance concept. TAG adds a unique ID number to each casting to provide the missing link between individual scrapped castings and their process parameters like sand compressibility, shot pressure and pouring temperature. TAG tracking also paves the way for advanced machine-learning-based analysis of scrap causes.

The trailblazing Mould Accuracy Controller (MAC) forms the second plank of DISA’s ZDM strategy. The MAC alerts operators to mould mismatches and gaps – causing scrap, rework and damaging melt run-through – before the mould is poured. At GIFA 2019, visitors to the DISA stand can test drive the MAC using a DISAMATIC Digital Twin (a digital simulation of a moulding machine). They can change the virtual machine’s settings via a DISAMATIC D3 control panel and immediately see how those changes affect mould quality.

The ZDM solution is completed with the Monitizer. As the digital platform which collects and shares data between your foundry equipment, Monitizer keeps processes synchronised and delivers a full digital view of real-time and historic foundry data.

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