The digitalization of die casting production refers to the realization of digitalization from all aspects of product mold design, raw material supply, production monitoring, quality monitoring and finished product warehouse management, and the realization of interconnection and sharing of these digital information. The information generated from all aspects is collected into the production management system (MES), and the production management center grasps the production status according to the real-time data, and schedules and arranges the production efficiently and reasonably. Accurately meet the customer’s order demand, and ultimately achieve high efficiency and efficiency of the company’s operation.
If the digitalization of die casting production is extended to the company’s supplier management and customer management, PLM can be realized. Further extended to cost management and warehouse management, and the company’s ERP system docking, can realize the digital operation management of the whole company.
The development basis of digital die casting production
The development of modern industry, especially the development of automation, provides the industrial basis for the realization of digital die-casting production. Modern die casting machine has entered the era of industrial computer control, with the ability of real-time recording and storage of die casting process parameters, but also fully integrated the operation information of auxiliary equipment, including soup feeder, part taking machine, spray machine, mold temperature machine and vacuum machine and other auxiliary equipment. The main communication method between die casting machine and these auxiliary equipment is Profibus.
Another important aspect of digitization in die casting production is the widespread application of various digital sensors, mainly including pressure, temperature, displacement, thermal imager and visual recognition system, etc. These sensors lay the foundation for the realization of digitalization and even intelligence.
1.Digitization of die casting cells
Main data of die casting production process:
(1) Data of raw materials
The main components of raw materials test report, mechanical properties report and K value report.
(2) Mold data
There are mainly mold 3D model report, mold flow analysis report and mold preparation report.
(3) Data of die casting process
Die casting unit production state, die casting parameters, die temperature, liquid aluminum temperature and water and electricity and other basic production guarantee parameters.
(4) Quality data
Product full size inspection report, process size report, process surface quality report and process internal quality report.
(5) Production management data
Production order, material preparation report and product output report, production order and material preparation report from the company’s ERP system production plan, product output report from the production site bar code scanning system.
2.Intelligent interconnection of die casting digital units
The die-casting production unit based on the above data is a basic digital die-casting unit. The realization of the digitalization of the entire die-casting workshop also requires the establishment of intelligent interconnection of these die-casting units. At present, the main intelligent interconnection methods in China are DNC and MDC. DNC is “distributed numerical control”, that is, distributed digital control. It can realize two-way concurrent communication of all digital die-casting units through one server, and has functions such as remote communication and forced uploading. The MDC method is “manufacturing data collection”, or manufacturing data collection, which enables a single server to automatically collect 4 096 digital units simultaneously. It is compatible with die casting machines, robots and automated production lines.
On the basis of the establishment of digital production unit and intelligent interconnection, the establishment of digital management system can give full play to the digital function.
MES system is the center of digital die casting production. MES is the “manufacturing execution system”, that is, the manufacturing execution system. MES system refers to the shop-level management information system between the upper-level plan management system and the underlying industrial control, which provides the operators/managers with the plan execution, tracking and the current state of all resources (people, equipment, materials, customer requirements, etc.). MES system can optimize the management of the whole production process from order to product completion through information transmission.
When a real-time event occurs in the factory, MES can respond to it in time, report it, and guide and process it with the current accurate data. This rapid response to state changes enables MES to reduce the internal activities without added value, effectively guide the production and operation process of the factory, so that it can not only improve the timely delivery capacity of the factory, improve the flow performance of materials, but also improve the rate of return on production. MES also provides mission-critical information about product behavior within the enterprise and throughout the product supply chain through two-way direct communication.
The main role of MES system:
(1) Optimize the production and manufacturing management mode of enterprises, strengthen process management and control, and achieve the purpose of fine management.
(2) Strengthen the cooperative working capacity of all production departments, improve work efficiency and reduce production costs.
(3) Improve the timeliness and accuracy of statistical analysis of production data, avoid human interference, and promote the standardization of enterprise management.
(4) Provide effective and standardized management support for the quality inspection of products, intermediate products and raw materials.
(5) Real-time control of planning, scheduling, quality, process and device operation information, so that relevant departments can find and solve problems in time.
(6) Finally, MES system can be used to establish a standardized production management information platform, so that the internal control layer of the enterprise and the management of information interconnection, so as to improve the core competitiveness of enterprises.
MES system through digital production scheduling, digital production synergy and digital resources management and decision support, can promote scientific plan, production process, co-ordinated and production equipment and the depth of the fusion of informatization, and based on data analysis, decision support for enterprises to carry out transparent, quantitative management, can improve the production efficiency and product quality.