iSenseTM

: The Future of Advanced Diagnostics is Here and Advanced Melt Shop Automation

Charles H. Fink, Jr. | Inductotherm Corp. | Vice President-Customer Relations & Training

IMF Spring Meeting | April 8-10, 2019 | Hilton Garden Inn, Longview, Texas

030201

Predictive

Maintenance

Process

Optimization

Data Access

Analytics

Managers are able to visualize

and make sense of what is going

on in real time.

Processes can be optimized to

increase efficiency and

reduce costs.

Problems can be predicted using

analytics before they occur.

Automation Advantages

• iSense™ melt shop equipment data visualization system

Advanced Automation

Data Digitization

Data digitization is crucial because

every added sensor provides a clearer

picture of the digital melt shop.

Information, Parts and Drawings

Digital melt shops should provide

drawings and all information on its

counterpart, including drilling down to the

smallest parts.

Machine Learning

Machine learning takes the place of physical

workers within a digital melt shop to

analyze and optimize processes for you.

Interactive Graphics

Interactive graphics provide a human

interface and provide accurate interactive

representations of the real-world.

Secure Instant Digital Access

Secure instant digital access is

necessary for a digital melt shop.

Digital Melt Shop

Inductotherm’s vision is of a complete digital

melt shop to give an instant graphic

representation of real-world information,

in a digitized format.

Inductotherm’s Vision: The Digital Melt Shop

Data CollectionData Collection through wires, wireless technology, fiber optics, and the process of collecting from sensors, concentrating the data, and making it available though the industrial Ethernet.

Data StorageData storage is important for use in making it available through HMI’s, and available to machine learning algorithms, whether it is stored in the cloud or local server databases.

Smart SensorsTemperature Sensors, Water Flow Sensors, Voltage Sensors, Conductivity Sensors, Pressure Sensors, Position Sensors, Control Signal Diagnostic Sensors and more.

Furnace DataPower, Current, Voltage, kWH’s, Frequency, Inductance, Weight, Tilt Angle, Bath Temperature, On/Off States, Firing Pulse States, Alarm States and more.

SENSOR

NETWORK

Inductotherm’s Sensor Network

Melt Shop Control & Management System

Melt Shop Equipment Data Visualization System

iSense™ Technology

Provides complete data acquisition

• Network all

Inductotherm equipment,

including:

– PLCs

– Computers

– Boards

– Sensors

Easy-to-read, interactive graphics

• Quick, visual

representation of your equipment:

– Health

– Diagnostics

– Equipment

status

– Historical data

– Preventative

maintenance

Obtain all relevant data in one place

• Detailed

equipment information

• Access to:

– Part lists

– Equipment

drawings

– Reference media

– Diagnostics

Virtual touch screen• View data,

important alerts, spare parts lists,

drawings, manual and more. See

example below.

Complete, one source database

• Equipment data

management of:

– Configurations

– History

– Alerts

– Trending

Equipment drill down

• View equipment

components in great detail

– Control boards

– Connectors

– Test points

– Jumpers

and switch settings

Extra features

• IP camera functionality

• Multi-language

support

• Melt log reporting

Full access - anytime, anywhere

• Access and monitor your equipment 24/7/365

• Remote web client and mobile device access

• Web access using mobile devices

Mobile Applications

• Alarm information overlays in data trends

• Maintenance scheduling

• Maintenance logging/history

• Replacement parts quote generation

Future Features

Dotson – MN, USClow Valve – IA, US

Garbi - Spain

Mitsui Meehanite - Japan

iSense Systems in Operation.

iSense™ Systems Worldwide

ARMS® System: Protect Your People… And Your Profits

• Automated processes are precisely repeatable, ensuring consistency and improved productivity melt-after-melt

• Fewer workers may be needed for melt deck tasks

• Enhanced safety that may reduce worker compensation claims

• Better working conditions make it easier to recruit/retain workers

• Maximize production and efficiency

• Minimize cost & waste

• Enhance worker safety and reduce risk

• Reduce energy consumption

• Ensure consistency

• Increase worker retention and reduce workers’ compensation

Robots & Automation

• The innovative ARMS® System was introduced in 2007

• It’s goal was to relocate the furnace operator’s duties on the melt deck with a foundry robot for enhanced safety

• Automated processes are precisely repeatable, ensuring consistency and improved productivity melt-after-melt

• The ARMS® System can be configured for any size ferrous or nonferrous foundry

ARMS® (Automated Robotic Melt Shop) System

• Checking the bath ground

• Checking the bath temperature

• Slag removal

• Sampling and analyzing

• Add trim/coagulant materials

• Final temperature checking

• Pouring (tapping) out

ARMS® (Automated Robotic Melt Shop) System

10 tonne Furnace 10 tonne Furnace

ARMS® System Typical Layout

In Conclusion

• Technological advancements are happening virtually every day

• Seek out opportunities to enhance, save or reduce whenever possible by using advanced automation

• There are many possibilities, both large and small

Thank You. Any Questions?

Charles H. Fink, Jr.-Vice President-Customer Relations & Training

Contact Info

Inductotherm Corp. 10 Indel Avenue

PO Box 157 Rancocas, NJ 08073-0157

800-257-9527 609-267-9000609-267-3537 FAX856-912-1930 CELL

cfink@inductotherm.comwww.inductotherm.com