Figure 4: Consarc electromechanical raise lower system (left), and tilting-translate mechanisms (right). Consarc, continued from pg 19
There are several additional tips to be seriously considered from the preventive-predictive point of view: • Schedule maintenance based on usage
• Invest in operator training • Test lubricants frequently • Inspect regularly for signs of wear • Repair and refurbish rather than replace
• Adjust maintenance depending on the environment
• Balance production needs
3.5. Smarter Controls To achieve improved quality and yield, strategies to reduce scrap and scatter and improve general process consistency should be followed: • Create automatic recipes for melting, pouring, mould heating, mould withdrawal, etc.
• Target reduced cycle times improving the cost of operation.
• Control auxiliary items (water pumps / radiators) to stop them when not needed in an automated manner.
• Implement system time-outs to prevent background operation (i.e. operator forgets to shut off systems over the weekend). Include furnace 'off state' shut down function which ceases pump operation, etc. when not needed.
20 ❘ May 2024 ® Figure 5: OEE tracking screen on Consarc Scada controls.
4. Final Conclusions These are the main conclusions about this study: • The biggest challenge faced by current and future generations is the issue of climate change, and industries need to adapt to this scenario.
• In particular, the investment casting industry needs to face this challenge by utilizing furnaces designed for green and sustainable operation and extended machine life.
• The strategies presented in this article are focused on: ∗ Energy saving systems. ∗ Elimination of waste and fluids. ∗ Smarter processes.
∗ Reduce of downtimes/ consumption based on improved maintenance ideas.
• All of these ideas are win-win for the end user as it will save costs, especially if the casting scrap is reduced, which is always the biggest cost and impact.
5. References [1].
https://www.assofond.it/en/ foundries-and-circular-economy [2].
https://www.leybold.com/en
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