nadca - visi-trak - top aluminum die casting experts, …¼rgen wüst october 2008 nadca plant...

October 2008Jürgen Wüst

NADCAPlant Management Conference

2017

Control Upgrades

John Cleary – Aavid Allcast

Arick Kaschalk – Visi-Trak


John Cleary

35 Years foundry experience

31 Years HPDC experience

“The greatest enemy of knowledge is not ignorance, it is the

illusion of knowledge.”

― Daniel J. Boorstin, The Discoverers: A History of Man's Search to Know His World and Himself

http://www.goodreads.com/author/show/10378.Daniel_J_Boorstin

http://www.goodreads.com/work/quotes/743199


In The beginning

In 1982 when I was a young technician , I was taught that

there was 100 variables when making a die casting and if

you controlled 95 of them you had a good chance of

making an acceptable casting.


Today

With The Expectation Of Today’s Customers You Have To

Keep All 100 In Control And Need To Be Certain That You

Are Making A Quality Casting


Aavid Allcast

Partnered With Visi Trak

Aavid Allcast’s Journey To Process Control


Aavid Allcast

Partnered With Visi Trak

Installed our first monitor in 1998

Continued upgrades until all machined were monitored

Started with Sure Trak shot control with a shot end upgrade

on a 800 ton Prince in 2004 .

Upgraded a total of 7 Machines to date


Controlling your Variance

Sure Trak Control VS. PLC Machine Control

Where Is The Variance

Can You Control Your Variance?



Solenoid Operated Pilot Valves, LS, PLC control

vs. Sure Trak Controls



Sure Trak Control Of Your Intensification Pressure

The Benefits Of Time Delay For Intensification Pressure


Adding Control

We Added our First Control In 2004, This was Done During

The Remanufacture Of The Diecast Machine .

Continued With Upgrade on 3 More Machines Over The

Next Five Years


Visi Trak vs. OEM controls

2012 We Added A New Diecast Machine With OEM Shot

Control

Added a Second Machine 2013 With OEM Shot Control

Added Third Machine First Quarter 2014 With OEM Shot

Control



OEM Shot Control Pros

Integrated Well Into The Machine Design

Performed At A Very Acceptable Level

Controlled Both Shot Profile and Intensification Pressure



OEM Shot Control Cons

Need To Keep Many More Spare Parts In Inventory

Reduced Product Support

Difficulty To Train To Systems to the Process Control Team


Converting OEM Control To Sure Trak Controls

We Purchased 3 More Diecast Machines ,2 in 2014 4

Quarter and 1 2015 With Sure Trak Controls

At This Time We Also Made the Decision To Convert The

OEM Controls To Sure Trak Controls



The Process Was Very Efficient




Installed A Self Contained Visi Trak Control





Removed OEM Solenoid Valve Piloted Cartridge Style

Metering Valve .






Metering Valve .

Installed Olmsted SV Cartridge Valve Piloted By Woodward

Servo Valve




Installed Self Contained Visi Trak Control


Metering Valve .

Installed Olmsted SV Cartridge Valve Piloted By Woodward

Servo Valve

Interfaced the OEM Intensifier Pressure Proportional Valve

With The Visi Trak Control


OEM Installed Sure Trak Control


The Benefits of our Transition

Uniform Shot Controls Throughout Our Operation

Uniform Training For Process Control Technicians

Uniform Training For Maintenance Personnel

Reduced Inventory for Critical Spare Parts

Excellent Customer Support


New vs Upgrade

2017 Corvette Z06

- 6.2 Liter V8

- 650 hp

- 0-60: 3.6 sec

- 22 MPG

1994 Corvette ZR1

- 5.7 Liter V8

- 405 hp

- 0-60: 4.6 sec

- 27 MPG


New vs Upgrade

or

+

October 2008Jürgen Wüst*Source: NADCA State of the Die Casting Industry 2017


OEE = A x P x Q


Complete Die Casting Process Technology


Shot Control Objectives

Accurate and Precise: “Follow the Method”

OEE: Focus on A & Q metrics

Eliminate Flash

Scheduling & Flexibility

Low Operation Cost


Considerations (Upgrading Shot Control)

Overall Condition of the Machine

Hydraulic Layout

Cost

Layout of Facility

Market Demands

- Structural, Weldable, High Integrity

- Low Scrap Rates


Hydraulic Circuit Configuration


Olmsted SV Valve – Servo Piloted DIN Cartridge

Valve

• DIN 24342 – ISO 7368

• Engineered specifically for Slow, Fast & Low Impact Phases of Die Cast Process

• Lightweight Gate for Fast Nimble Response

• LVDT Feedback for Closed-Loop Control and Diagnostics


OBJECTIVES Improve Part Quality by increasing

Accuracy & Consistency of

- Slow/Int Shot Velocity

- Calculated Start of Fast Shot

- Fast Shot Velocity

- End of Shot Position

Reduce Occurrences of Flashing

Get machine back in Service ASAP

Decrease Machine Downtime & Maintenance Technician Time spent on Machines

Decrease Spare Part Replacement Buys

Improve Capability of the machine to meet market demands


Control Upgrades on DCM’s: 1200 Ton (1994)

OPERATOR SIDE: Upgrade installed in August 2014


Control Upgrades on DCM’s: 1200 Ton (1994)

HELPER

SIDE:

Upgrade

installed in

August 2014


Statistical Analysis


SHOT TRACE


RESULTS 3-5 day turnaround for Install

Statistical Analysis Revealed Accuracy and Consistency showed Marked Improvement

Flashing Occurrences almost completely eliminated

20% Increase in Machine Utilization

8 Month ROI, made up of Increased Machine Uptime, Less Maintenance Time on Machine, No Components Replaced, Eliminating Leaks on Shot End Hydraulic Circuit, Decreased Scrap & many others…

Machine now capable of handling advanced castings because of improved injection performance

http://www.visi-trak.com/wp-content/uploads/2017/05/Metaldyne-Article-

Die-Casting-Engineer-July-2016.pdf

http://www.visi-trak.com/wp-content/uploads/2017/05/Metaldyne-Article-Die-Casting-Engineer-July-2016.pdf


OEE = A x P x QA: Availability or Uptime (Run Time / Planned Production Time)

P: Performance (Ideal Cycle Time x Total Count)/Run Time

Q: Quality (Good Shots / Total Shots)

90% x 90% x 90% = 73% OEE

World Class OEE: 85%


? If you are running at a 20% Scrap Rate, how many parts do

you have to produce to get 100 Good Parts?

- A) 120 x 80% = 96

- B) 124 x 80% = 99

- C) 125 x 80% = 100

Are you capturing all of the costs associated with Scrap?


Why is Downtime Different in Die Casting?

Before you can

proceed into

production, you must

first attain Thermal

Balance of your die


‘F’ Word

Flashing!

Safety Issue

Causes Downtime

Lowers Die Life

Potential Damage to Property


Hydraulic Leaks


Shot Control Checklist

High Performance Valves

Closed Loop Control

Filtration

Hydraulic Piping for Laminar Flow


Which path should you choose?

Do

No

thin

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Va

cu

um

Sys

tem

Me

ch

an

ica

l

Au

tom

ati

on

Inje

cti

on

Co

ntr

ol

Availability

Performance

Quality

Cost $ $0 $$ $$$ $$

ROI $


Questions?John Cleary

Aavid Allcast

Office: 262-629-5566

[email protected]

Arick KaschalkVisi-Trak Worldwide, LLC

Office: (216) 524-2363

[email protected]

tel://(216) 524-2363/

mailto:[email protected]

nadca - visi-trak - top aluminum die casting experts, …¼rgen wüst october 2008 nadca plant...

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