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GIS Foundry Information System

In modern foundries, a large number of process variables must be monitored, controlled and documented.

The GIS software has a modular design, it collects, distributes and documents all relevant process and production data in a foundry. The collection of production data from our software in a central database allows for a continuous tracing of the casting process from the base material to the finished casting. It is the tool of choice for the foundry engineer to describe the relationships between process, structure and properties of cast products.

The configuration of the GIS is specially adapted to the foundry processes, to make the data collection as efficient as possible. For the data exchange with plant controllers and measuring devices, a variety of interface modules are available.

The data source can be accessed and recorded automatically or manually and varies from raw material analysis, melting, treatment and pouring protocol, Thermal analysis, spectrometer, C/S combustion analysis, sand laboratory, mechanical properties results, image analysis and finished part testing.

Through the central data-base, all process data is comfortably available to all users.

Based on the parts or material specifications, the compliance with the specifications is constantly controlled during production and any deviation is signalled with a colour marking.

The optimization of the process is facilitated by regression tools and interdependencies of certain process parameter can be easily calculated and verified.

GIS Base module

The GIS-Base Module provides comfortable access to the results of thermal analysis, temperature measurement and laboratory analyses in tabular and graphic mode within the network. Histogram charts and a regression function for controlling the %C and %Si determination via thermal analysis complete the set of functions.

The specifications for materials, castings, raw materials and the system configuration are maintained in the GIS master data administration:

  • Materials grades with analysis specifications
  • Castings with part-specific specifications:
    • Analysis specifications
    • Weight, dimensions and design
    • Casting parameters (temperature, duration, inoculation, ...)
    • Specifications of mechanical properties
  • Alloy material specifications
  • Casting inspection specification: type and location of test, classification, defect

The master data will be stored in the data-base with a version tracking system, to ensure that changes to the specifications are recorded for documentation.

The GIS-Charge Calculator offers a customized charging process, adapted to the characteristics of your melting procedure.

Charge Makeup calculator
  • Optimization of the charge make-up to minimize costs
  • Interactive process control during weighing of raw materials
  • Alloy calculation after completion of the raw material type
  • Flexible mixture management
  • inventory management
  • Interfaces to crane PLCs and scales
  • Interface to dosing systems

The GIS – Melt Report is used for documentation and control of the melting process.

GIS Melt Report
  • Heat information
  • Charge data
  • Analysis management for thermal and chemical analyses
  • Calculation of final adjustments to the melt composition
  • Tracking of the tapping and transfer procedures
  • Statistic evaluation of consumption and cost

The process data can be automatically transferred to the SPC module to manage SPC control charts.

SPC
  • Automatic transfer of process data or optional manual acquisition
  • Interactive acknowledgement process
  • Documentation of all interventions
  • Flexible evaluation over longer periods of time
  • Permanent link to the respective valid specifications (version tracking)

The results from the material tests at the laboratory can be made available in the GIS-Laboratory Data module.

  • Mechanical Properties
  • Tensile test bar
  • Hardness
  • Charpy test
  • Ultrasonic test
  • Dumping
  • Microstructure evaluation

The results from the material tests will be automatically collated to the corresponding production and analysis data, to allow an efficient record tracking and process evaluation.

GIS - Spectro Import

Using the GIS SpectroImport module, the results of a spectrometer's chemical analysis can be automatically imported into the GIS database. The information is also matched to the respective furnace or production charge number following configurable criterions.

The spectrometers from the following suppliers can be connected:

Spectro, OBLF, Thermo Scientific ARL, Leco

Connection to other equipment supplier’s also possible, if requested.

GIS Interface Modules

The GIS can use several interface modules to connect to numerous peripheral systems in the foundry, such as:

  • ERP Systems: IPS GussExpert, RGU, SAP
  • Moulding lines: HWS, Künkel-Wagner
  • Furnaces: Junker, Inductotherm, ABP
  • Dosing systems
  • Charging cranes
Molding material database

In foundries, the monitoring and documentation of sand systems is becoming increasingly important. With the help of the moulding sand database you can comfortably manage the data of your sand laboratory.

  • Data management of the sand laboratory according to VDG standards
  • Variable inspection scope
  • Integration of measurement data from online systems
  • Evaluation and trend tracking
  • Report generation

The software can be flexibly adapted to the inspection scope of the moulding and core sand systems. For an optimal overview, the sampling points of all systems can be defined hierarchically structured in the system, standard and special test ranges can be created for each sampling point.

At the end of the analysis, the results can be retrieved from the database, printed as a report or sent by e-mail. Various presentation options are available for the evaluation of the results, e.g. the chronological course of one or more test values can be displayed in a user-definable diagram or a statistical evaluation can be carried out via the histogram module.

The Micr-O-Phase program is an image analysis specialized in cast iron that has been designed to quickly measure a large number of images in order to achieve a high level of statistical certainty.

Micr-O-Phase
  • Automatic graphite shape analysis: Form I (A, D, E), III, IV, V, VI
  • Analysis of perlite/ferrite percentage
  • Generation of individual reports

The system evaluates any number of images per sample. Both mean values and analyses of the individual images are available.

With our OCC-PhaseCam with C-Mount adapter, older microscopes can also be retrofitted with the Micr-O-Phase image analysis system.

The implementation of customer-specific algorithms offers the possibility to transfer special evaluation methods into the program.

The data from the image analysis can be directly linked to the data from the process and are immediately available for evaluation.

Evaluation of cause/effect relation between process parameters and casting defects or properties.

CSL

Regressions:

  • Linear
  • Use of multiple variables for regression
  • Allows the application of mathematical functions to the variables, such as x2; x3; 1/x; Ln(x); exp(x)
  • Graphical display of the regression results and related parameters such as: Correlation coefficient, T-test, Deviation
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