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A quantum leap for diecasting control

What use is the best machine if its application is too complex and overwhelms the user? This question led Bühler engineers to completely redesign the control of diecasting machines enabling them to take a quantum leap in the control of diecasting cells, says the company.

Complex systems, overloaded operators

Controlling complete diecasting cells requires complex and capable systems. These have to control and monitor not only the actual diecasting process, but also cover the peripherals of a diecasting cell – dosing, the removal robot, spraying systems, trimming press, vacuum systems, the conveyor, as well as forming and temperature control systems. Keeping the relevant process information manageable and getting to the crux of the matter is not always easy. “You make excellent systems, but users are overwhelmed with the operation,” was a common complaint.

The development team at Bühler Die Casting took this customer feedback to heart. Together with specialists in user interface design, they fundamentally redesigned the operation of diecasting controls. With the innovative user interface DataView, they took a quantum leap towards intuitive machine control. “It is as if we had switched from Windows 95 to a modern operating system,” says Laszlo Jud, head of automation at the company. The first prototype was presented at the last GIFA foundry trade fair in Düsseldorf. Since then, the solution has been successfully put into operation for select customers to demonstrate the reliability of the system in the harsh foundry environment.

Intuitive control

“With DataView we have developed a control system that is distinguished by convenience and intuitive operation. Similar to a smartphone,” says Mimmo Chieco, product manager for DataView. The diecasting cell can be operated via a touch screen and minimal manual control elements. The latter is particularly important when the industry environment only permits rough handling. The timesavings for operators are clear – the fast and intuitive control reduces programming time by up to 25 per cent. In addition, the time required for maintenance and training is significantly lower. And lastly, pilot customers appreciate being able to access data in real time via mobile devices such as tablets.

Steps towards the Internet of Things

DataView is enabling diecasting to take its first steps towards the Internet of Things. “All operations and changes are captured digitally. We can reconstruct and optimise each millisecond of the diecasting process,” said Jud. This has significant advantages, especially with regards to recalls in the automotive industry. Thanks to precise traceability, it is now possible to accurately isolate faulty pressure castings. “It makes a difference whether 20,000 parts have to be recalled or only 2,000,” says Chieco. The diverse diagnostic options are another advantage of the new machine control. In a simple manner, even ‘health checks’ can be carried out in real time as well as monitoring of a machine’s condition. They can be used, for example, to monitor and optimise energy consumption of the various elements of a diecasting cell. And the inventors have already begun thinking about the next step. “Diagnosis is good, but prognosis is better,” says Jud. “With the data generated, we will be able to identify and prevent potential problems in advance within the next few years.” Currently, developers are working on making the clear advantages of this innovative system available for other series, such as the Evolution. The customers show their thanks with positive feedback: “The operation is simply more intuitive, which is visible immediately. All information that is relevant for operation is always available. It’s impressive,” says Srdjan Paunovic, head of foundry at Wagner AG in Switzerland. www.buhlergroup.com