Foundry Automation.ppt

8/9/2019 Foundry Automation.ppt

1/24

Foundry Mechanization &Automation

Aneesh Kumar. P

Roll No: 412114001

11!2014 1


2/24

Presentation o"er"ie#

$ntroduction to Foundry & %astin

'imitations o( (oundry industry

Areas (or mechanization &automation

Ro)otic automation

%om*uter in (oundry +o(t#are *ac,aes (or (oundry

11!2014 2


3/24

Foundry & %astin

A foundryis a (actory that *roducesmetal castings.

Castingis one o( the most im*ortant and

maor *rocesses o( manu(acturin in#hich sha*ed articles can )e made in asinle ste* )y *ourin molten metal intomould and allo#in the melt to solidi(y

#ithin it. /he mould contains a ca"ity*roduced )y the *attern #hoseeometry determines the eact sha*e o(the article or com*onent.

11!2014 3


4/24

Main limitation to (oundryindustry

/he safety hazards to human)eins es*ecially #hen hot metaland alloys are handled.

Produce some environmentalproblems.

11!2014 4


5/24

Modernization mechanization

automation 5hy6 /o #or,ers 7

$m*ro"ed #or,in condition

8nsure a sa(e healthy and ha**y li(e

/o o#ners 7

9iher *roducti"ity & 'o#er reection

$m*ro"ed uality

Reduction in *roduction cost

;etter com*any imae +troner Partnershi*s &im*ro"ed mar,etin

Kee* *ace #ith the chanin technoloy

11!2014


6/24

Areas (or mechanizationand automation

Material handlin

9andlin o( sand Moldin and %ore ma,in

Meltin Pourin and sha,eout

o*erations %ontrol o( dust and (umes

11!2014 !


7/24

Material handlin

$n"alua)le asset in the ra*id andeconomic *roduction o( castins on alare scale.

8=cient handlin o( items such as > +and mould and cores molten metal

castins

;elt con"eyors ;uc,et ele"ator a*ron con"eyor

Fliht con"eyor Reci*rocatin and oscillatincon"eyors monorail con"eyor cranes.

Roller con"eyor *allet con"eyor o"erhead

con"eyor $ndustrial truc,s ro)ots

11!2014 ?


8/24

Material handlin

11!2014 @

Belt Conveyor Bucket elevator

Pneumatic ConveyorRoller Conveyor Pallet Conveyor


9/24

+and *re*aration andcontrol

%ontinuous Mier

Molda)ility controller 7 +lotted "i)ratory(eeder

$nterated systems

+and *re*aration #ith mied resin sandcontinuously discharin into a moldin

)o *laced on "i)ratory com*action ta)lea *attern loo*> mould stri**in de"iceand a sha,e out #ith a reclamation *lant.

11!2014

+ d i d


10/24

+and *re*aration andcontrol

11!2014 10

Sand Preparation Mixer

Continuous Mixer

Mobile Mixer

Mobility Controller


11/24

Moldin and %ore> Ma,in

Po#er o*erated moldin machines

9ih *ressure moldin machines

%ore 7 )lo#in machine

%ore dra#in machines

%ontinuous core ma,in machines

11!2014 11


12/24

Moldin and %ore> Ma,in

11!2014 12

Sand Molding Automated

Molding MachineAutomated Molding


13/24

Meltin Pourin andsha,eout eBui*ments

Machineries are de*loyed de*ends on (actorssuch as >

/y*e and condition o( eBui*ment

8conomical (easi)ility A"aila)ility o( Coor s*ace

Automatic *ourin system

%rane li(t truc, turno"er truc, )elt

con"eyor

Di)ratin ty*e sha,e out ;um)er ty*e sha,eout

11!2014 13


14/24

Meltin Pourin andsha,eout eBui*ments

11!2014 14

Melt Shop

Knockout Machine


15/24

%ontrol o( dust and (umes

Fine *articles o( sa# dust in the *atternsho*

5hen sand is mied and *re*ared durin

moldin sha,eout (etin o*eration Fumes durin meltin metal trans(er

*ourin o*eration.

%yclone Filter 8lectrostatic *reci*itatorMechanical collectors +cru))ers A(ter)urners.

11!2014 1ProductIH/PH/+Finished

products

11!2014


17/24

%ontrol o( dust and (umes

11!2014 1?

Dust Collector Working principle - Induced electrostatic charge


18/24

Ro)otic automation

Many o*erations that are *er(ormedin a (oundry are ideally suited (orro)otic automation )ecause they are

>

/hree EJs > dirty danerous and dull.

/hree 9Js > hot hea"y andhazardous.

%ontd.

11!2014 1@


19/24

HnimateJ/he Grst industrial ro)ot

$n 1


20/24

%om*uters in (oundries

Product desin and Analysis/rans(errin eometric in(ormation (rom

human mind to a com*uter

F8M +imulation o( +tress +train 9eattrans(er Di)ration Fatiue Fracture

%AM +imulate machinin I*erationAccurate and automatic calculation o(

eometric *ro*erties

%ontd.

11!2014 20


21/24

%astin desin and simulation

%on"ert *art desin to toolin desin sho#in orientation in the mould *artinline a**lication o( dra(t and allo#ances

atin and (eedin system core )oes*attern *lates and other elements

CastCHECK 7 ;ased on numericalsimulation

$dea to ma,e (ast casta)ility analysis

Eesin the com*lete castin system #ithriser slee"es ates chills cores and moulds

11!2014 21


22/24

+o(t#are *ac,aes (or(oundry use

Magmasoft Optimization of casting and foundry processes CastCAE Mould lling and solidication simulation

A!" "olid #$$$ Accurate prediction of shrin%ageporosity

&ova!lo' and &ova"olid ( Mould lling andsolidication )roCA"* +eveloped by ,E" "oft'are

,sing !E techni-ues 'ith thermal calc database

"imulating solidication process

Mesh CA"* !ully automatic + mesh generation AutoCA"* Kno'ledge based system for Cast design

decision/ cast model creation and process simulation

11!2014 22


23/24

$ntellient Ad"isory +ystems

;ased on

eometric reasonin

$n"ol"es understandin the *art model and

reconizin the rele"ant (eatures

Kno#lede enineerin

$n"ol"es storin and lin,in domain,no#lede #ith a com*uter *roram (or)etter decision su**ort to the users

11!2014 23


24/24

/han, Lou

11!2014 24

Foundry Automation.ppt

Documents

Transcript of Foundry Automation.ppt