isense tm : the future of advanced diagnostics is here and
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iSenseTM
: The Future of Advanced Diagnostics is Here and Advanced Melt Shop Automation
Charles H. Fink, Jr. | Inductotherm Corp. | Vice President-Customer Relations & Training
IMF Spring Meeting | April 8-10, 2019 | Hilton Garden Inn, Longview, Texas
030201
Predictive
Maintenance
Process
Optimization
Data Access
Analytics
Managers are able to visualize
and make sense of what is going
on in real time.
Processes can be optimized to
increase efficiency and
reduce costs.
Problems can be predicted using
analytics before they occur.
Automation Advantages
Data Digitization
Data digitization is crucial because
every added sensor provides a clearer
picture of the digital melt shop.
Information, Parts and Drawings
Digital melt shops should provide
drawings and all information on its
counterpart, including drilling down to the
smallest parts.
Machine Learning
Machine learning takes the place of physical
workers within a digital melt shop to
analyze and optimize processes for you.
Interactive Graphics
Interactive graphics provide a human
interface and provide accurate interactive
representations of the real-world.
Secure Instant Digital Access
Secure instant digital access is
necessary for a digital melt shop.
Digital Melt Shop
Inductotherm’s vision is of a complete digital
melt shop to give an instant graphic
representation of real-world information,
in a digitized format.
Inductotherm’s Vision: The Digital Melt Shop
Data CollectionData Collection through wires, wireless technology, fiber optics, and the process of collecting from sensors, concentrating the data, and making it available though the industrial Ethernet.
Data StorageData storage is important for use in making it available through HMI’s, and available to machine learning algorithms, whether it is stored in the cloud or local server databases.
Smart SensorsTemperature Sensors, Water Flow Sensors, Voltage Sensors, Conductivity Sensors, Pressure Sensors, Position Sensors, Control Signal Diagnostic Sensors and more.
Furnace DataPower, Current, Voltage, kWH’s, Frequency, Inductance, Weight, Tilt Angle, Bath Temperature, On/Off States, Firing Pulse States, Alarm States and more.
SENSOR
NETWORK
Inductotherm’s Sensor Network
iSense™ Technology
Provides complete data acquisition
• Network all
Inductotherm equipment,
including:
– PLCs
– Computers
– Boards
– Sensors
Easy-to-read, interactive graphics
• Quick, visual
representation of your equipment:
– Health
– Diagnostics
– Equipment
status
– Historical data
– Preventative
maintenance
Obtain all relevant data in one place
• Detailed
equipment information
• Access to:
– Part lists
– Equipment
drawings
– Reference media
– Diagnostics
Virtual touch screen• View data,
important alerts, spare parts lists,
drawings, manual and more. See
example below.
Complete, one source database
• Equipment data
management of:
– Configurations
– History
– Alerts
– Trending
Equipment drill down
• View equipment
components in great detail
– Control boards
– Connectors
– Test points
– Jumpers
and switch settings
Full access - anytime, anywhere
• Access and monitor your equipment 24/7/365
• Remote web client and mobile device access
• Web access using mobile devices
Mobile Applications
• Alarm information overlays in data trends
• Maintenance scheduling
• Maintenance logging/history
• Replacement parts quote generation
Future Features
Dotson – MN, USClow Valve – IA, US
Garbi - Spain
Mitsui Meehanite - Japan
iSense Systems in Operation.
iSense™ Systems Worldwide
ARMS® System: Protect Your People… And Your Profits
• Automated processes are precisely repeatable, ensuring consistency and improved productivity melt-after-melt
• Fewer workers may be needed for melt deck tasks
• Enhanced safety that may reduce worker compensation claims
• Better working conditions make it easier to recruit/retain workers
• Maximize production and efficiency
• Minimize cost & waste
• Enhance worker safety and reduce risk
• Reduce energy consumption
• Ensure consistency
• Increase worker retention and reduce workers’ compensation
Robots & Automation
• The innovative ARMS® System was introduced in 2007
• It’s goal was to relocate the furnace operator’s duties on the melt deck with a foundry robot for enhanced safety
• Automated processes are precisely repeatable, ensuring consistency and improved productivity melt-after-melt
• The ARMS® System can be configured for any size ferrous or nonferrous foundry
ARMS® (Automated Robotic Melt Shop) System
• Checking the bath ground
• Checking the bath temperature
• Slag removal
• Sampling and analyzing
• Add trim/coagulant materials
• Final temperature checking
• Pouring (tapping) out
ARMS® (Automated Robotic Melt Shop) System
In Conclusion
• Technological advancements are happening virtually every day
• Seek out opportunities to enhance, save or reduce whenever possible by using advanced automation
• There are many possibilities, both large and small
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