Effective Digitalization for Molding Sand Preparation

Two years ago Eirich Group introduced a camera-based system for optical quality assessment of silica granules in foundry sand preparation processes. Combining advanced camera technology with AI-based analysis software, it evaluates variables like particle-size distribution, grain shape, and grain surface to be measured. And the data obtained in that process is available to inform various other control platforms in place to optimize casting quality and production efficiency.

Foundry sand preparation is just one of several industrial markets in which Eirich is active, and Qualimaster is a technology series the group has been offering for in-line process monitoring across many of them. Now, as metalcasters recognize the necessity to enhance process efficiency, as well as energy efficiency, it is introducing a new option for foundry modernization and digitalization.

“Many machines from the 1980-90s and 2000s still work perfectly but their control systems are technologically outdated,” according to Eirich. “New plants or large investments are not always necessary; retrofitting and minor modernization measures are often enough to bring them up to date.”

Improving energy efficiency and lowering their carbon footprints are the major objectives for most foundries, Eirich further noted.

Preparing molding sand for producing quality castings involves systems that combine sand mixing and compacting, consistently. The targets are exacting compliance with compactability specifications, plus sand flowability, uniform strength values, and optimal gas permeability.

Eirich systems combine return sand, new sand. and additives, and complete distribution of water in the mixture. To optimize the process, Eirich’s emphasis use of sensor-based technologies at specific process points – with “innovative control logic for sand preparation”.

The QualiMaster “intelligent” sand management technology models daily sand orders and calculates new sand and additive requirements in advance. The AT1 inline testing device provides compatibility and shear strength values with three measurements per batch within 40 seconds. Those readings are recorded and analyzed using the SandReport software.

With relevant batch data from the prepared molding sand and a moisture-correction tool (AC1), the sand system is controlled according to a foundry’s specifications and corrected if necessary.

Intelligent sand management is carried out using Eirich’s SandExpert software, with predictive calculation of new sand and additive requirements. According to the developer, this means that the molding plant always has the right sand material available for the respective casting product.

“Used sand is replenished with just as much bentonite, new sand, and additives as it loses during the subsequent molding process,” according to Eirich. This conserves resources and saves time, and as a result the foundry operators achieve effective raw material management, with maximum flexibility for production planning as well as process stability and reproducible results.

Eirich argues that digitalization of metalcasting is important for the future viability of the industry, and that in many cases, artificial intelligence will improve finished casting quality and thereby reduce reject rates.

"There are still unfounded reservations when it comes to digitalization. AI is primarily used to support skilled workers. The strength of these tools lies in their ability to interpret a large amount of collected data in a specific context and thus provide a sound basis for decision-making. Through continuous learning, almost 100% accuracy can be achieved when forecasting technical production parameters," stated Eirich sales manager Maria-Luise Liepe.

Those tools also support production efficiency. Boundaries between control systems can be overcome with combined data analysis from molding material preparation and the casting operation, as well as intelligent sensor technology and data analysis software.