Mold by mold control
In the iron casting process, especially in the case of green sand moulds, the significant variability of the critical parameters of the different sub-processes requires complex procedures for process control. In addition, to ensure quality, the components are subjected to different types of quality controls and costly visual inspections.
These controls include both controls aimed at ensuring metallurgical quality, checking aspects such as nodularity, carbides, matrix structure or the internal health of the parts (X-rays, ultrasound), as well as controls associated with process problems, such as cold joints, carbides, lack of material or inclusions.
Predictive Control Systems aimed at ensuring product quality
It is proposed to treat each mould as if it were a series. Using digital twins of different phases of the process fed with real-time data, predictive control systems make it possible to detect process imbalances in order to identify moulds at risk of defects and propose corrective actions aimed at avoiding the appearance of defects. Thanks to this, it is possible to reduce the quality controls applied throughout the process.
With a Zero Defects horizon and in order to improve the efficiency of the process by reducing the number of controls throughout the process, AZTERLAN has developed the Mold-to-Mold Metallurgical Control system, based on digital twins of the manufacturing process and the implementation of MPC.
Actions carried out:
- Identification of key process parameters that affect the final production result
- Development of a digital twin of the process: Plan and system for capturing, traceability and storing process data
- Establishment of control of the inoculation flow and the casting process
- Establishment of cause-effect correlations between process parameters and final result and development of Predictive Control Models (MPC)
- Implementation of MPC in digital twins of the plant for the generation of real-time alerts
- Development of a mold segregation system prior to shake-out
- Development and implementation of query and management interfaces for different job profiles in the plant: workforce and plant management (business)
Solutions applied:
Digital Twin for the mold by mold control of the cooling line implemented at AAPICO Portugal
- Reduction of rejections due to metallurgical causes
- Reduction of quality controls
- Reduction of customer complaints
- Optimization of overall process performance (the relationship between the amount of metal used and parts produced)
- Reduction of energy and materials consumption
- Optimization of the reliability and efficiency of the manufacturing process