DIGITAL PASSPORT – Access to manufacturing data traceability of castings
Sistema de control predictivo por inteligencia artificial.
Predicción de la calidad del proceso de fabricación de componentes metálicos.
The Digital Passport is a components’ unique record that collects the whole traceability of its manufacturing process. It provides access to the data collected along the different phases of the foundry process by means of a unique ID engraved on the surface of the part and a compatible display system.
The Digital Passport is mainly aimed at building a more robust part by part quality control. However, this solution also opens a wide range of possibilities for the exploitation of control data to optimize the efficiency of the process and ensure the soundness and quality of the components manufactured. These data also make it possible to perform several advanced studies.
This is how it works
Molds have a unique identification code that will leave a singular sign on the surface of every component.
This identification element can be replaced by a label or other surface engraving system making it possible to assign a unique code to the parts that can be read by compatible image processors.
an image processor provides access to the unique manufacturing record of each part.Integrated in an app installed on a Smartphone or by means of a QR or barcode reader,
The Digital Passport gathers all the parameters controlled and stored throughout the different phases of the manufacturing process.
Among the stored data, some basic data can be highlighted such as: manufacturing date, casting identification, chemical composition, inoculation process, results of thermal analysis, etc., as well as other more specific data such as: location of the part within the mold, characteristics of the mold, carbon footprint, incidents or other key events happened during the manufacturing process, etc. that have been monitored and traced.
- Data standardization: Data must be presented in a language that allows these to be read and interpreted by the systems developed for this purpose.
- High storage capacity and shared registry.
- Security of the storage system and connections: Security standards, mainly, aimed at ensuring the integrity of the registered information and that data can not be altered by unauthorized actors.
- Global access: The data contained in the record must be accessible by means of the devices and routes established with this aim.
Development opportunities
Advanced applications of the Digital Passport
The analysis of the defective parts detected during quality controls can offer keys to establish cause-effect relationships.
Likewise, this is information of great value to feed back the plant control system, favoring the development of Predictive Control Models aimed at optimizing the foundry process.
When part by part controls are not carried out on 100% of production the Digital Passport facilitates to identifify of potentially defective parts that share risk factors with rejected components.
This same philosophy can be applied when an in-service-failure study points to the manufacturing process as the cause and origin.
At the end of life of equipment and components, Digital Passport makes it possible to know the specific chemical composition of the parts. Additions made for protection purposes (on the surface) or during assembling (e.g. welding) could also be recorded. This information helps to define the most appropriate recovery and/or reuse methods.
Component’s Digital Passport can also be fed throughout its useful life by adding data reflecting their in-service behavior.
This data can help relate manufacturing characteristics and performance.
“The Foundry of the Future is that of connected processes that is able to take advantage of the knowledge generated inside the company at the same time that it keeps learning from its manufacturing and market experience.
Along with a deep knowledge of metallurgy, Industry 4.0 technologies, advanced data management systems and machine learning technologies have landed in this industry to transform the way castings are conceived”.
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