CPT International 3/2019

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INTERVIEW Is operation of the systems becoming easier? Eric Bader: With the integration into Industry 4.0, which we are now implementing with our new partner, the fears about the complexity of the technology should disappear because transparency has increased. There is a camera image from the box on which you can observe the printing process layer-by-layer. That should lower the hurdle to enter 3-D printer technology. How important is Germany as a market for 3-D printing technology? Eric Bader: The country is at the top of the ladder, we have some companies in here that are pushing the technology to its limits. There are foundries that have their own sorting process. Suddenly, there is space for many other applications that are possible with the 3-D printer. Apart from Germany, there are also other prime examples, such as the Japanese-American company Kimura, which has more than ten of our machines. The company has completely switched from traditional core and mold making to 3-D printing. It is important for companies to become owners of a machine. It is not enough to be supplied with 3-D printed products. We have to use the machines ourselves to understand the possibilities. “We print with inorganic binders – this is a trend that will affect the entire industry,” Eric Bader predicts. Who are your customers in the foundry industry? Eric Bader: Georg Fischer, Gießerei Grunewald and many more. Most of the automotive companies in Europe, the Americas, India and China are utilizing 3-D printing technology. 70 - 80 percent are running on our printing equipment. The pump industry is interesting, aerospace is very interesting, the building equipment industry, and parts of general industry too. These are the markets that we are in today. We certainly have a solid backbone in the automotive industry but the technology is now spreading out into other diverse industries. John Hartner: Many of our customers have already placed follow-up orders with us. We also have the largest market share. Ford is a good example. Recently, two brand new systems were deployed at their Advanced Manufacturing Center in Detroit. The center is one of our oldest customers. So business in the US is going well too? John Hartner: We are just negotiating with representatives of a construction equipment company. Yes, business in the US is going well. But we also have a very large customer in Japan, for example, who in turn has customers who demand high levels of complexity and who want to automate more because of the shortage of skilled workers. How about the environmental friendliness of your technology? Eric Bader: The pressure in terms of climate protection weighs on all companies. We print with inorganic binders – this is a trend that will affect the whole industry. In addition, we also work with chemical and natural resources companies to produce binders with low emissions. We are currently trying to reduce the emissions of furan resin binder systems. What is decisive for the ecological footprint, however, is that 3-D printing no longer necessarily means that products need to be shipped, but that the data can simply be sent to a printer in another country and printed there. This gives you the flexibility to produce the parts where you need them. We saw some interesting developments at GIFA: what do you think of the entry of Laempe Mössner Sinto into the production of 3-D printers, or the alliance for 3-D printing involving Loramendi, voxeljet and ASK Chemicals? John Hartner: The market is growing, interest is increasing. However the market develops, we will be able to handle it and improve even further! Eric Bader and John Hartner spoke with Robert Piterek 8
MELTING SHOP Photo: Andreas Bednareck Digitalization in industrial furnace manufacturing – on the way to Industry 4.0 OCP system in use. In contrast to the previous version, the current one enables cross-system communication and standardized data exchange. The way to Industry 4.0 is an evolutionary process which offers great potential for improving and stabilizing production processes and for increasing energy and resource efficiency by way of digitalization and networking. As a leading supplier to foundries and semis producers, Otto Junker GmbH (Simmerath/Germany), is determined to meet this challenge as demonstrated herein on the examples of its OCP Optical Coil Protection system, predictive maintenance system, and process models (Digital Twins). by Felix Aßmann, Simon Künne, Kunal Mody, Wilfried Schmitz and Günter Valder Introduction While the automation level and hence, the degree of digitalization of modern industrial furnace equipment, be it melting or heat treatment systems, has kept rising in recent years, these systems and the associated peripherals have, in many cases, largely remained digital islands to this day. Although extensive digital networking and the consistent acquisition and, above all, consolidation of all available data for the purposes of comprehensive higher-level analysis within the meaning of Industry 4.0 is well underway in foundries and semifinished product manufacturing plants, there are still many steps that remain to be taken. Otto Junker CASTING PLANT & TECHNOLOGY 3/<strong>2019</strong> 9
Page 3 and 4: EDITORIAL Converting big data to sm
Page 5 and 6: CONTENTS MELTING SHOP Digitalizatio
Page 7: ExOne’s current business strategy
Page 11 and 12: Figure 2: Arrangement of the OCP se
Page 13 and 14: Arranged around the furnace are the
Page 15 and 16: a b c d e f Figure 9 a-f: Modelling
Page 17 and 18: An initial recipe is now selected f
Page 19 and 20: SAND REGENERATION Perfection is the
Page 21 and 22: Everything in view at all times All
Page 23 and 24: MOLD AND COREMAKING Equipment desig
Page 25 and 26: The Koenig & Bauer Foundry GmbH, W
Page 27 and 28: Likewise, it is now possible to dis
Page 29 and 30: Managing Director Frieder Spannagel
Page 31 and 32: those of Latin America. Orders from
Page 33 and 34: COMPANY For exports - which account
Page 35 and 36: CASTING Special GIFA 2019 Part 3: O
Page 37 and 38: trade fair, and there were even tra
Page 39 and 40: SPECIAL: GIFA 2019 The die-casting
Page 41 and 42: At its stand, ABP showed how custom
Page 43 and 44: SPECIAL: GIFA 2019 FOSECO Flow cont
Page 45 and 46: E-MOBILITY cradle-to-grave consider
Page 47 and 48: Figure 7: The monovalent gas engine
Page 49 and 50: FRAUNHOFER IFAM Low-cost powders de
Page 51 and 52: OSKAR FRECH GROUP Huge investments
Page 53 and 54: SPEKTRO Analyzer for Process Contro
Page 55 and 56: SUPPLIERS GUIDE CASTING PLANT AND T
Page 57 and 58: 08.02 Moulding and Coremaking Machi
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▼ Annealing Furnaces 7490 19 Patt
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30 Data Processing Technology 31.02
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04.02. Refractory Materials (Shaped
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3660 Molochite 3670 Mullite Chamott
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6110 Electrical and Electronic Cont
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8690 Synthetic Resins for Patternma
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11125 Sealing and Insulating Produc
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INTERNATIONAL FAIRS AND CONGRESSES
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CPT International 3/2019

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