CPT International 04/2017

INTERVIEW
from the use of embedded chips over
current conventional identification
methods. The essential effect lies in
functional integration and improved
quality assurance through a consistent
tracking of individual components all
the way to the component’s application
in the whole system. In particular,
their use in quality assurance can deliver
entirely new possibilities of storing
process, customer, or quality-related
data as these can be stored directly
within the casting or linked using the
code and archived. Hereby, the integration
of a transponder – which we have
labeled “casttronics” – ensures the maximum
protection against product piracy
while offering a broad range of additional
functions for the customer – for
example regarding component logistics,
assembly, and service. This can generate
added value for the customer, possibly
as far as creating new business models.
Currently, the casting industry is seeing
a trend towards Foundry 4.0. How
strategy for a “smart foundry”?
Pille: Initially, at its core the main
thrust of the embedding of RFID transponders
was in a different direction
than has typically been discussed under
the title of “Foundry 4.0”, which
is generally in regards to the consistency
and networking of individual
processes. However, with the embedding
of RFID chips we primarily aim at
the ability to clearly identify individual
components within a series – and
thus at specific traceability as well as
continuous tracking and tracing within
the concept of intralogistics. We understand
a casting with an integrated
chip as an “enabler” in order to implement
the concepts of Industry 4.0 into
the production of a particular casting
and to realize an interface between
the casting and process management.
Although the castings will not yet be
able to “speak”, they will nevertheless
possess a great deal more intelligence
than previously. In the future, we aim
to include integrated sensor technology
into such concepts; these will be
able to provide information about the
condition of the casting. For example,
the casting will be able to record the
heat treatment process, report on it,
and halt the process when the desired
values have been reached.
The process was developed in the
framework of a project called MUSIC.
What was that about? Were there further
project partners?
Pille: The acronym “MUSIC” stands
for “Multi-layers control and cognitive
system to drive metal and plastic
production lines for injected components”.
In other words, the aim was
an autonomous in-line quality control
for aluminum high pressure die
casting and plastic injection molding.
This included not only being able to
predict the quality of the casting, but
also, with the help of cognitive calculations
such as comprehensive system
sensor technology, to enable the high
pressure casting machine to determine
and evaluate casting errors autonomously,
recognize the necessary adjusting
screws in the process, and conduct
a new parameterization in order
to reduce the number of casting errors
or even to completely eliminate these.
The project, which ended in 2016, involved
a total of 16 partners from various
EU countries, including the foundry
colleagues from Hochschule Aalen,
Audi and RDS as casting manufacturers,
the equipment manufacturers
Frech and RegloPlas, the sensor suppliers
Electronics and Motul, and the
simulation partner MAGMA.
For which foundries is the Cast tronics
process, i.e. embedding RFID chips,
suitable?
Pille: The technology is applicable for
any foundry that intends to take advantage
of RFID technology, as well as
where there is customer demand for added
value of the product. Economically,
the process is likely to be of use for castings
that already have high added value
and where individual identification as
well as the possibility for data and information
storage directly onto the casting
would increase added value. However,
we do already have partners where the
customer has already demanded RFID
technology and has also proportionally
carried the additional costs.
In addition to the introduction of
Casttronics technology, are further
large-scale facility adaptations necessary
in order to utilize the full potential
of embedded RFID chips?
Pille: No. The installation of the read/
write systems and the accompanying
8 Casting Plant & Technology 4 / 2017