With the continuous promotion of Industry 4.0, intelligent manufacturing has become an important trend in the development of the manufacturing industry. As a metal forming process, die casting is widely applied in various fields such as automotive, 3C, and electronics. However, traditional die casting production processes face problems such as information silos, low production efficiency, and unstable quality control.
The smart die casting solution has emerged to bring revolutionary changes to the foundry industry by integrating advanced technologies such as the Internet of Things (IoT), cloud computing, big data analytics, and artificial intelligence (AI). This innovative solution enables intelligent management of foundries, significantly enhancing production efficiency and product quality while effectively reducing production costs. 1.Equipment Networking and Information-based
Production:Building the Cornerstone for Digital Factories
The primary step of the smart die casting solution is to achieve equipment networking and comprehensive informatization of production processes. To this end, we have introduced Yi CMS (Equipment Networking and Condition Monitoring System) and Yi MES (Manufacturing Execution System). These two systems enable enterprises to digitize production scheduling, management oversight, quality assurance protocols, warehousing and logistics, personnel management, and equipment data collection and maintenance management. The core value of this module lies in making the production process transparent and enabling real-time monitoring, which lays essential foundation for subsequent data analysis and intelligent optimization.YIZUMI Condition Monitoring System (Yi CMS)
Yi CMS is a key bridge connecting the production lines with automated equipment alongside other physical entities to MES system. It undertakes the collection of vital production data, comprehensive monitoring of operational workflows, and strict control over production quality.
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YIZUMI Manufacturing Execution System (Yi MES)
Yi MES is an integral framework governing both control and management of the entire production workflow by meticulously monitoring output generation, task allocation, and progress tracking at each stage of manufacturing. By leveraging MES system, enterprises can achieve refined management of the production process, enhancing production efficiency and response speed. The MES system enables real-time collection of diverse datasets from on-site operations, providing strong, accurate information support for production decision-making.
2. Die Casting Data
Analysis Platform:
UncoveringData Value
Building upon equipment
networking and information-based production, the smart die casting solution
further establishes a closed-loop data analysis platform for die casting quality. With big data technology at its core, this platform efficiently completes the cleaning, processing, and feature extraction of process big data by integrating data resources
from the Yi CMS and Yi MES systems. On this basis, we have developed digital
models and data analysis tools for the processes, providing robust data support
for process optimization and quality control.Process Data Cleansing and Processing
Big data is the cornerstone
of intelligent manufacturing. A vast amount of data is generated in the die
casting production process, including equipment operating data, production
process data, and quality inspection data. However, these data often contain a
large amount of noise and outliers, necessitating advanced data cleaning and processing technologies to extract valuable information.
The process digital model
is fundamental for achieving process optimization and quality control. By
analyzing the characteristics and patternsof the die casting processes, we have
constructed a precise mathematical model for the process. This model can simulate and
predict various complex situations in the production process, providing a solid
theoretical basis for optimizing process parameters, and helping enterprises
achieve more efficient production and stricter quality control.
Digital analysis tools are
key to achieving process optimization and quality control. By developing and
applying various data analysis algorithms and tools, we can delve into
production data and uncover potential patterns and problems in the production process, thus
providing scientific evidence for production decision-making.3. Intelligent
Process-aided Commissioning:
Innovation of Process Management
Intelligent process-aided
commissioning is an integral part of the smart die casting solution. Leveraging
a big data platform, it utilizes process knowledge mining technology and
an intelligent process optimization assistant to provide comprehensive digital
and intelligent commissioning services for remote process distribution and
diagnosis. Implementing this module enhances the accuracy and efficiency of process
adjustments, significantly minimizing the impact of human factors on production.![]()
Process Knowledge Mining Technology
Process knowledge plays a
key role in the die casting production. With the assistance of process
knowledge mining technology, we extract process patterns and practical experience
from massive production data and establish a process knowledge base. The
knowledge helps guide the setting and adjustment of process parameters and
improve process stability and product qualification rate.Intelligent Process Optimization Assistant
The intelligent process
optimization assistant is essential for achieving process intelligence. It
automatically adjusts process parameters and optimizes processes based on the established
rules and models within the process knowledge base. Additionally, it can
dynamically modify these parameters in response to real-time data feedback
during production, ensuring the stability of the entire production.
Remote Process Distribution and Diagnosis
Remote process distribution
and diagnosis are vital components for realizing process intelligence. The
remote process distribution system enables the transmission of optimized
process parameters directly to the production site, enhancing the efficiency of
process adjustments. The remote diagnosis system allows for real-time
monitoring of the production process and timely detection and resolution of any
issues that may arise.
4. Model-based Quality
Sorting:
Improving Process Management Efficiency
Quality is the backbone of
the manufacturing industry. The smart die casting solution implements a
model-based quality sorting mechanism by integrating machine learning to
provide abnormal quality alerts, intelligent sorting of defective products, and
root cause analysis. The module leverages big data analyses and machine learning
algorithms to monitor and analyze quality data in real time during the
production process. It enables therapid detection and effective resolution of
quality issues,and enhances the efficiency of product quality inspections while reducing
inspection costs.Abnormal quality alerts
serve as the first step in the quality sorting process. The system can predict
and identify potential quality defects through real-time monitoring of quality
data during the production process and in-depth analysis of quality data using
machine learning algorithms. Upon finding a defect, the system promptly issues
an alert, allowing enterprises to implement measures and avoid the production
of batches of defective products.Sorting of Defective Products
The sorting of defective
products is a critical step of quality control. Utilizing advanced technologies
like image recognition and machine vision, the system can automatically and
accurately identify and sort outdefective products, significantly enhancing the
efficiency and precision of quality control.Quality Root Cause Analysis
Quality root cause analysis
plays a vital role in improving product quality. By thoroughly analyzing the
underlying causes of quality issues, we can address them at their source,
thereby enhancing product reliability and stability and ensuring continuous product
quality optimization.
5. Dynamic Optimization
of Control
Parameters:Pursuing Extreme Accuracy
Optimizing control
parameters is vital in the die casting production process. The smart die casting
solution offers dynamic optimization of these parameters through technologies
such as intelligent locking force and intelligent mold opening and closing. This module can
automatically and accurately adjust various die casting machine control
parameters based on real-time production data and comprehensive historical data
analysis, ensuring production process stability and high-accuracy product
output.![]()
The smart die casting
solution integrates five core modules to realize digital, intelligent, and
automated die casting production. The solution not only enhances production
efficiency and product quality, but also effectively reduces production costs
and energy consumption, providing essential technical support for the
sustainable development of enterprises. As technology continues to advance and
be used in practical sectors, smart die casting solutions are poised to play an
increasingly vital role in the future of the manufacturing industry.
