EASYpour™ upgrades already existing pouring systems with technological perfection. Based on gained experiences over decades of pouring and the use of components of IoT lead to take the next step in automation. With EASYpour™ every pouring process is performed and adapted automatically and intelligent. Not only the stopper moves automatically, but the casting parameters are also adjusted and changed during the process to the advantage of the pouring. The system is suitable for gray, mellable, ductile, CGI and mixed production.
Algorithms for Artificial Intelligence were developed, necessary accessories were put together and intensively tested together with various foundries. With each phase of this development it has become clear that this special application has the potential for direct use as an advanced level of AI. Every time the system learns independently in order to optimize itself, the green learning bar in the top right of the picture moves up. After the first pouring cycle of a new pattern has been completed the Stopper offset and TT (Total Time)are included in the optimization together with the other parameters. The green bars above and below the two parameters light up during optimization and show the direction and intensity of the action. Two graphs are placed on the left of the screen. The upper graph shows the (green) calculated iron level, which is necessary for a clean filling of the pouring cup. The actual filling level, which results from the reaction of the stopper, is shown by the uneven (yellow) line. The two thicker red lines at 66 and 100 represent the lower and upper boundaries of the pouring cup. The “Level” parameter was set 96. This means 4 mm below the top of the mould (as the top of mould is defined as 100). The stopper opens up to the selected maximum distance of 12 mm between the nozzle and the tip of the stopper. At the beginning the pouring, the stopper is opened up at maximum speed up to the limit, for the fastest possible filling of the pouring cup. This is intended to prevent ambient air from being sucked into the gating system, causing oxide formation. The maximum speed of the stopper movement is 100 mm per second. The maximum flow rate of iron is reached at a distance of about 30 millimeters between the stopper and the nozzle. Thus, the stopper is opened in a few tenths of a second and therefore react very quickly. The pouring time and the flow rate are adapted to the need for a smooth and repeatable mould filling thanks to the precise laser measurement.