Manufacturing Flexibility and Internal Part Traceability in Foundry Automation

Abstract

The phd project started with a literature review and identification of research gaps in the areas of interest identified by Jøtul, the lead foundry in the Autocast foundry consortium and discussion with advisor. The thesis covers the results of two focus areas. The described results were also presented during the quarterly meetings organized by the consortium during the phd project timeframe (Jan 2010- Jan 2013)

Focus Area I Laboratory experiments were conducted to estimate holding forces generated from the probable range of electromagnet voltages during industrial use. A milling machine setup at the laboratory at NTNU Valgrinda was used for experiments. The distance of the electromagnet from the cast iron plate was controlled by the vertical motion of the milling machine. The vertical holding forces were measured with a National Instruments data acquisition system. The holding forces were simulated using a commercial software and qualitative explanation of the deviations of the model compared to experiments is also provided. The same experimental set-up were used to estimate friction values one could expect for the material pair in action. Since the cast iron parts are much harder than the gripper material, rapid wear of the electromagnet was observed.

Focus Area II This focus area describes a methodology for internal traceability and proposes a control plan documentation approach. The industrial need for developing traceability systems originates from regulations, standards and customer specific requirements.

The Phd requirements from the ad published by Autocast 2009:

The leading Norwegian manufactures of castings for the international market need new technology to meet the international competition and the environment-, health- and safety requirements. This implies a considerable emphasis on the development of new technology to enhance the use of automation and robotics in the foundries. The work will include development of both theoretical methods and physical laboratory demonstrations of the technological solutions. The candidate is expected to have a close connection with AutoCast’s industrial partners during the entire extension of the PhD project, in particular with the project owner Jøtul, and use these as living labs.