SinterCast in Hall 10, Stand B39 System 4000
product launch SinterCast Cast Tracker
[Düsseldorf, 25 June 2019] - At the GIFA world foundry trade fair, held every four years in Düsseldorf, SinterCast has today launched the fourth generation of its Compacted Graphite Iron (CGI) process control technology - the System 4000. SinterCast has also taken the opportunity of the GIFA trade fair to present its new Tracking Technologies - SinterCast Ladle Tracker® and SinterCast Cast Tracker™ - for traceability and process optimisation in ferrous and non-ferrous foundries, and in other metallurgical facilities. The suite of SinterCast technologies on display, representing 54 installations in 14 countries, provides solutions for high volume, niche volume and rapid prototype production of CGI, and for Industry 4.0 traceability of the liquid metal, the core packages, the moulds, and of every individual casting. In parallel with the opening of GIFA 2019, SinterCast has also launched a new website: www.sintercast.com
System 4000 - Fourth Generation CGI Process Control
Building on the production of more than 15 million CGI components, SinterCast has developed a series of technology upgrades that combine to form the company's fourth generation process control technology for the reliable series production of CGI. Branded as the System 4000, the upgrade includes Version 7.0 of the SinterCast metallurgical software; increased computing power with a new Windows® embedded operating system to enable integration of the SinterCast Tracking Technologies; larger operator interface for increased flexibility of information display and improved user-friendliness; new signal lamps for improved operator interaction; ethernet communication to increase the speed and security of information exchange; laser-monitoring of the Thermocouple Pair position throughout the thermal analysis; and, remote data access to allow managers to view the production status on any internet-connected device. All process settings and series production results are available to the foundry engineers in a comprehensive database that can be downloaded or streamed directly to the foundry ERP system. Available as the Mini-System 4000 for prototyping, product development and niche volume series production; the System 4000 for measure-and-correct series production; or, as the System 4000 Plus for high volume production with automated base treatment, the System 4000 maintains the proven modular hardware format that suits the process flow and layout of any foundry. The System 4000 can be configured for foundries that produce CGI from pressurised pouring furnaces or by pouring ladles.
SinterCast Tracking Technologies
Ladle Tracker: With robust RFID tags affixed to every ladle and antennas located at key positions throughout the foundry, the SinterCast Ladle Tracker ensures that every ladle reports to every step in the process and that every step is completed within the specified process limits. Ladle Tracker also identifies where and why ladles fall-out of the process, enabling foundry managers to measure, control and improve process efficiency and productivity. The complete process data for each unique Melt ID is compiled in a database that can be downloaded or streamed directly to the foundry ERP system.
Cast Tracker: Based on the unique labelling of each core package, Cast Tracker uses optical camera recognition to monitor and control the progress of every core package through assembly, coating, drying, storage and moulding. As the core packages are set into moulds, RFID tags affixed to each flask extend the traceability to casting and shakeout. Cast Tracker ensures that every core package is within specification prior to casting; identifies the cast sequence within the ladle; and, measures the shake-out time. The Cast Tracker results are compiled into a database to allow engineers and managers to improve process efficiency and to troubleshoot the foundry process, identifying and eliminating the root cause of casting defects. Together, the Ladle Tracker and Cast Tracker technologies bring Industry 4.0 traceability to the foundry industry, evolving castings from batch commodity products into unique individual components with fully documented production histories.
New Website Launched
SinterCast has also taken the opportunity of the GIFA trade fair to launch a new website, www.sintercast.com. In conjunction with the launch of the new website, SinterCast will be initiating an enhanced LinkedIn campaign, reaching out to customers, suppliers and shareholders to invite all of our stakeholders to follow us on LinkedIn.
"Since the last GIFA in 2015, our CGI series production has grown by 45%; the number of SinterCast installations has increased by 30%; we have introduced our new Ladle Tracker and Cast Tracker technologies; and today, we have launched the fourth generation of our CGI process control technology" said Dr Steve Dawson, President & CEO of SinterCast. "With this progress behind us, we look forward to showcasing our process control technologies and to hosting our current and potential customers from around the world. We also look forward to continuing to develop and launch new technologies, bringing more precision measurements - and more control - to our foundry customers."
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