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Smart Energy Management Network for the HPDC process of aluminum alloys

Customer – ChemTrend – Inprotec IRT
Trial with interactive DTC – Robot spray
Complex and heavy parts – 8kg GH

Main targets

  • Interactive control DTC – ABB Robot
    Avoid soldering and stopped machine occurrences
  • Understand and define the best warm-up curve
    Increase productivity and reduce scrap
  • Improve OEE
    Overall equipment effectiveness of the HPDC cell

Results

Warm-up

Productivity

Stopped machine
(thermal reasons)

Estimated monthly cost for a 2,700 tons DCM stopped:
  • In 22 working days: 52 hours stopped
  • 150 €/hour (estimation from a DCM producer)
  • In 22 working days: 52 hours stopped
  • Good interaction between DTC-ABB Lubrication Robot
    Variation of the lubrication cycle according to DTC alarm limits
  • Reduction in the defect occurrences
  • Optimization of the die lubrication cycle
    Wastewater reduction
  • Improvement of 3.5% in OEE
    Overall equipment effectiveness of the HPDC cell

Conclusions

  • The DTC is an «open» device:
    Interface with peripheral devices is real
  • The DTC is a monitoring device for the series production:
    Productivity improvement
  • Tailor-made on Customer’s needs

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