investment in this technology has been well justified.
Q You easily identify any VA Technology installation when
visiting any investment casting foundry, as the design style and well structured lay outs are talking by themselves, but in addition there is a word displayed on the robots “Shellmaker”. I understand that was the name of the first software that you personally developed. Can you tell us on the software developments and evolution along those years and the improved functionalities achieved?
A
Many ‘firsts’ were achieved at the outset. From the start, the complete shell manufacturing systems delivered were computer controlled from a central PC, and the first version of Shellmaker was launched. Initially it was called CD1 and then
at the first customer training session, the end user attendees referred to the system as the Shellmaker that was it! CD1 was first on display at the ICI
in 1990 and then superceeded after a couple of systems with CD2, operating in DOS and written in C and this went on to be developed and utilised in more than 100 systems worldwide. This system became a
standard within the industry and provided
for full shellroom
de-facto process
control of single or multiple systems, networked together, and accessible across the internet. In 2005, CD2 was replaced with
the more advanced and user friendly IC-QL which was Windows-based and provided all the tools and powerful capability that Windows offered. All elements of the previous system were enhanced and the system capability was greatly expanded.
Process
data management, total foundry integration and IT standardisation were strengthened. Ten years later, a new level of process capability was achieved with the release of IC-Crystal.
This
new system represented a great leap forward in every aspect of the System Process
management and performance. ® capability The platform and structure for advanced remote data
access for production and process management, and most importantly Advanced Servicing capability and support was greatly enhanced. With IC-Connect, developed by the same team, the whole shellroom system process environment was opened to authorised handheld device access. The IC-Crystal
control capability
places the shellroom at the forefront group of the Investment Casting Process Technologies… and who knows where the next 30 years will take the investment casting process, and for sure it will be exciting!
Q The involvement of VA
Technology in providing solutions for the shellroom implied not only the aspects we have been discussing about the core equipment for shell making but all sort of auxiliary equipment that
in their integration
constitute a manufacturing system. Can you tell us about the equipment and the associated challenges both in functionality, process control and system integration?
A
Ceramic pre-mix, in-cell slurry ma- chines, supplementary equipment for pattern cleaning, slurry KPV mon- itoring, automatic dosing machines, in-line and in cell shell weighing and measuring systems and many more ma- chines have been developed.
Industry
sector specific machines include high speed spinning machines, plate edge cleaning machines and slurry coat flu- idity assist machines. Ceramics slurries are applied to the
shell through immersion, flow jet, or flow coat techniques, and in-cell slurry capacities have been installed ranging from 100kg all the way up to 20 tons. Stucco application machines have been engineered for rotary, vertical oscillatory, or fluidizing application… enabling the application of stuccos for shell structural and preferred porosity characteristics. Developing the machine technolo-
gies to deliver the requirements engen- ders great teamwork at all skill levels and professions within the engineering team, and nothing gives greater satis- faction to a design engineer than to see the fruits of his team efforts translate from concept into the actual reality of a working machine or system. Getting it right has helped expand the indus- try from small and medium sized parts production, to encompass the manu- facture of large castings, each weighing several tons. The design and development of intelligent conveying systems to transfer shells with payload capacities from 100kg to 1500kg has also been
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