VComp-SP® Case Study
Goals:
To dynamically predict compactability set point using IIoT-based data analytics approach to achieve target lab Compactability for better mould integrity & therefore, casting outcomes.
Background
The VComp case study was carried out at a renowned casting manufacturer in Northern India, having manufacturing capacity of 25,000 tons/annum. The bunch weight exhibited variations ranging from 15 to 34 kg, while the sand-to-metal ratio spanned from 4 to 10. Additionally, the average weight of the cores used in the casting process was measured at 0.4 kg, with a wide variation from 0 to 1.77 kg.
The foundry was facing high variability in the moisture content of the prepared sand and inconsistency in lab Compactability. These inconsistencies led to sub-optimal mould quality and related rejection rates. To address this, the foundry implemented VComp-SP®, an IIoT driven advanced data analytics software solution.
With VComp-SP ®, the foundry gained near precise control over the moisture content of the prepared sand and achieved consistent lab Compactability in close tolerances. The software provided the capability to dynamically adjust the Compactability set-point based on the specific characteristics of the return sand, ambient conditions, and casting requirements. By leveraging the power of IIoT and data analytics, the foundry optimized the Compactability set-point to minimize variations and ensure optimal casting performance.
The successful implementation of Sandman VComp-SP® resulted in improved rejection rates and enhanced operational efficiency for the foundry. The precise control over moisture and Compactability, combined with the variable set-point prescription, significantly reduced casting defects and enhanced overall quality.
