CPT International 02/2019

SPECIAL: GIFA 2019
DISA
Premieres of game-changing foundry innovations
for Zero Defect Manufacturing
At GIFA 2019, DISA,
Taastrup, Denmark,
will reveal three radical
new digitally-driven
innovations that move
foundries closer to
Zero Defect Manufacturing (ZDM). Inspired
by DISA’s unmatched experience
in helping customers continuously
improve casting quality, these cutting-edge
ZDM solutions – the novel
Trace and Guidance (TAG) concept, the
patent-pending Mold Accuracy Controller
(MAC) and the upgraded Monitizer
– open the door to a new era of
scrap elimination.
Visitors to the DISA section of the
Norican Group stand will have hands-on
access to both hardware and digital
models so they can see for themselves
how process data, real-time analysis and
forensic quality control combine to help
trace and eliminate scrap. “Finding the
root cause of scrap can be extremely
difficult,” says Per Larsen, Portfolio and
Innovation Manager at DISA. “The total
quality-related costs across foundries
and casting users can represent up to
10 % of the casting price.”
For the first time ever, foundries can
gain full traceability with DISA’s ingenious
new Trace and Guidance (TAG)
concept. TAG adds a unique ID number
to each casting to provide the missing
link between individual scrapped castings
and their process parameters like
sand compressibility, shot pressure and
pouring temperature. TAG tracking
also paves the way for advanced
machine-learning-based analysis of
scrap causes.
“TAG tracking promises to be a
major game changer for our industry,
helping drive down quality-related costs
to previously unseen levels,” says Larsen.
“GIFA visitors will be able to
explore the patent-pending TAG design
for themselves in the demonstration
area on our stand and sign up for exclusive
news as this exciting concept is
developed further.”
The trailblazing Mold Accuracy Controller
(MAC) forms the second plank of
DISA’s ZDM strategy. The MAC alerts
operators to mold mismatches and gaps
– causing scrap, rework and damaging
melt run-through – before the mold is
DISA CIM (Computer Integrated Modules), featuring a completely new suite of data analysis
and alerting tools
poured. At GIFA 2019, visitors to the
DISA stand can test drive the MAC using
a Disamatic Digital Twin (a digital simulation
of a molding machine). They can
change the virtual machine’s settings
via a Disamatic D3 control panel and
immediately see how those changes
affect mold quality.
“Delegates can inspect a full-size
MAC on the stand, then use the Digital
Twin to virtually test how the MAC
monitors the molding machine’s output
and helps spot any developing problems,”
explains Larsen. “They will get a
real feel for how operators are kept
fully informed and can react to quality
issues seconds after they first appear
and, most importantly, before pouring
the molds.”
The MAC will be released at GIFA as
a retrofit option for Disamatic machines
with Automatic Mold Conveyors, helping
more customers wave goodbye to
scrap.
GIFA also sees the release of Monitizer
| CIM, DISA’s third ZDM solution.
This is the next generation of DISA CIM
(Computer Integrated Modules), featuring
a completely new suite of data
analysis and alerting tools.
As the digital platform which collects
and shares data between your
foundry equipment, Monitizer keeps
processes synchronized and delivers a
full digital view of real-time and historic
foundry data. Monitizer | CLOUD from
Norican Group extends the platform,
using IIoT technology to collect, monitor,
and analyse complete foundry data
from one or multiple global foundry
sites.
“With the Disamatic Digital Twin,
MAC, TAG, and Monitizer, visitors can
see how DISA’s disruptive digital innovations
make it possible to “dive into the
data” to troubleshoot problems, optimize
critical foundry processes and take
major steps towards zero scrap,” states
Larsen.
During on-stand sessions and within
the official GIFA lecture programme,
DISA experts will discuss how its ZDM
solutions enable the data-driven
foundry and help improve productivity,
quality and resource utilization.
Hall 11, stand A74-A78
www.disagroup.com
Photo: Disa
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