|
Project Profile: Molding Machine Controls Optimization
The Challenge: The customer is a tier 1 automotive parts supplier that produces the vast majority of
North American-made exhaust manifolds. They sought to improve the operational efficiency
of an existing flaskless
automated molding machine. The machine builder was not providing the technical
support required to ramp up the operational performance of the machines.
The Solution: The project involved 3 specific applications:
- E-Stop Modifications: The line was originally set up with only one
emergency stop relay, and hitting the E-Stop halted the entire line. Stopping
the entire line, however, was not always the appropriate answer to operational
problems, as it resulted in molds being destroyed. A new control philosophy was
implemented to rectify the existing system. E-Stops were separated so that the
Pouring/Cooling area could be stopped without affecting the operations of the
molding area.
- Filter Change Controls: The existing vacuum pumps were equipped
with filters that stopped sand from entering the pump; the operators were
required to change the filters according to a preventive maintenance schedule.
The customer’s operators, however, were not consistently changing the filters
according to the schedule. To remedy this, a differential pressure switch that
kicks the machine out of automatic operation as soon as the filter begins to
plug up was added. The operators cannot revert back to automatic operations
until they have changed the filter.
- Vacuum Box Cleaning Automation: Fines removal from the vacuum box
area originally required operator manual intervention. A system comprising a
vacuum box conveyor and fines-collection chute was installed to remove the
fines from the vacuum box area. Control software was added to operate the
vacuum box conveyor and the fines-collection chute valve controls.
|
