Noricanのアルミ鋳造

廃棄物ゼロ、不良ゼロ、シームレス統合

炉のエネルギーを節約し、鋳物の品質を向上させ、鋳物工場のコスト効率を向上させます。:
どのようにして?

これらは、アルミニウムの使用量が急増しているトレンドのほんの一部です。:

-自動車の軽量化とe-モビリティの台頭

-5G技術の進歩

-リサイクル性の向上を求める社会的要求の高まり、プラスチック使用の拒否反応の広まり

アルミニウムの利点:リサイクル性と廃棄物の削減

アルミニウムの使用量が増加している基本的な理由は、リサイクル性と廃棄物削減の点で他の材料よりも優れていることです。
ニアネットシェイプ製造では、機械加工が少ない分、材料の無駄も少なく済みます。アルミニウムの特性(可鍛性を含む)は、この利点を活用して原材料効率を改善するのに特に適しています。

ダイカストの欠点:資源とエネルギーの利用率が高い

アルミニウムダイキャスト作業は、資源とエネルギーを大量に消費します。ダイカスト部品のトータルコストの約25%がエネルギー消費に関連しています。

アルミニウム鋳物工場は、エネルギーとリソースの使用量を最小限に抑えながら材料効率を最大化し、競争の激しい市場で最適な部品品質を保証するため、継続的な改善を行うにはどうすればよいのでしょうか?

欠陥ゼロ:廃棄を減らす、良品を増やす

この難しいバランスを取るための答えは、「ゼロ」です。

これは何もしないという意味ではありません。廃棄物(エネルギーと資源)ゼロ、不良ゼロの戦略に集中することを意味します。なぜなら、機器の能力の進化と新たなデジタルソリューションのおかげで、この2つは手を取り合うことができるからです。また、この戦略を採用すれば、急速に進化するアルミニウム市場における他の重要な課題にも

1. 大型で複雑な構造のアルミ部品の需要の増加

 複雑な構造の部品は、優れた強度と剛性と可能な限り低い重量を組み合わせ、より高い機械的性能要件を満たすために「欠陥ゼロ」でなければなりません。しかし、それらはまた、実用的な課題をもたらします。たとえば、炉に収まるように手動でピースを切断して再溶融する必要がある場合、時間と人的資源を浪費する可能性があります。この問題を解決するために、StrikoWestofen社のBigStruc(構造部品専用溶解炉)が開発されました。

2. 開発サイクルの短縮とテクノロジーの急速な変化

これら2つの要因により、新しい鋳造ラインでは多くの場合、図面作成から生産までの時間が大幅に短縮され、無駄(非効率)が障害となっています。一方で、サプライチェーンの遅延を引き起こす可能性のあるものは、ラインの末端で発見された品質問題を含めて、効率を最大化するために特定して対処しなければなりません。

3.持続可能な生産

持続可能な生産は、エネルギー消費やコストの削減だけではありません。持続可能な生産は、長期的な生産を脅かす要因(計画外の不要なダウンタイム)を排除することも意味します。鋳物工場は、稼働時間を最適化し、最初から最適な生産を実現する無駄のないソリューションに焦点を当てる必要があります。

From furnace to finished casting

At Norican and across our four technology brands, we can take a full-process view from melting to cleaning – to develop innovations and solutions that help customers achieve zero waste and zero defect ambitions and tackle these challenges.

Let’s take a look at the potential.

1. Optimising furnace efficiency

The melt shop offers opportunities to save huge amounts of energy and money, but also for increased automation to make production more agile and less reliant on manual intervention

With an energy consumption rate of just 489 kWh/t and a near 100% metal yield (99.75) for improved quality, StrikoMelter is the most efficient melting furnace on the market. 

StrikoWestofen’s Part Load Efficiency Control boosts melting process efficiency – especially during low utilization – by optimizing melting and holding over longer periods, reducing energy consumption by up to 20%. 

Together these solutions help customers save money, time and make more of their resources. 

 

Monitizer | Refill Monitor: This digital solution from StrikoWestofen uses real time sensor-generated data to ensure aluminium dosing furnaces never run dry and only ever receive the right alloy at the right time. This prevents unnecessary filling runs, avoidable stoppages and guarantees that dosing and bale-out equipment is always working at full capacity. 

Productivity of metal supply increases by 15% at least and, on average, an overall productivity increase of between 0.5% -1% is achieved thanks to reducing downtime and optimized filling cycles. More uptime, more accuracy, more profitable production. 

Click here to see how you can reduce energy wastage when melting and transferring aluminium.

2. Aluminium die casting performance

Zero waste, zero defect isn’t just a mantra with melt shop benefits. In order to cope with the new wave of larger, often more complex structural parts in high demand, High Pressure Die Casting (HPDC) machines with greater clamping forces are necessary, ranging from 3,500 tons at the lower end of the scale, to 5,600 tons. If additional space is required to accommodate these giants, it can impact on production flow/capacity; wasted space can effectively equate to lost potential. Also, such machines need to have extremely tight die closures in order to eliminate scrap and avoidable flash for high-quality part repeatability (zero defect).

The compact Toggle Free solution

Italpresse Gauss offers deliberately compact, toggle-free HPDC machines with rigid, tight, closing units and a range of clamping forces – delivering the advantage of greater force and larger platens, without taking up additional space on the foundry floor.

The zero waste, zero defect ethos is designed into all our aluminium solutions and services, not just individually, but collectively as a Norican complete foundry solution. This includes high performance green sand options from DISA – who has adopted Zero Defect Manufacturing as their ultimate customer offer.

The Complete Aluminium Foundry

Italpresse Gauss’ automated work cells are designed to optimise cycle time and stability for improved quality casting with less energy wastage, and to seamlessly integrate periphery equipment such as StrikoWestofen’s Westomat dosing furnace. 

The Westomat requires just a third of the energy consumed by automatic ladle systems while also reducing metal loss by about 80% compared to a holding furnace.

After casting, comes surface preparation.

 

3. Shot blasting aluminium

Aluminium production settings demand lighter, more flexible and more compact shot blast equipment. Wheelabrator has recently extended its most popular shot blast machine ranges with models that are tailored to aluminium applications.

Wheelabrator's blast machines for aluminium integrate into tight cell layouts to provide compact, seamless material and workpiece handling, with flexible construction that allows equipment to be moved and adapted quickly to suit rapidly changing production requirements.

Space is maximized, downtime is minimized, and - thanks to innovative engineering tailored for precision blasting, descaling/deburring, deflashing and cleaning of aluminium parts – finished part quality is optimised.

Everything works together collectively for seamless efficiency. From start to finish.
From the metal melting furnace right through to the casting’s final surface preparation.

The complete high pressure die casting foundry

featuring melting and dosing technology from StrikoWestofen, high pressure die casting technology from Italpresse gauss, and shot blast LBS machine from Wheelabrator.

Digital transformation for die casting

Leveraging Industry 4.0

On the subject of ‘collective’ efficiency for zero waste, zero defect super-productivity, one of the other key tools at the disposal of aluminium foundries is Data.

Casting yield, scrap rate, cycle times and number of shifts per day: these are just a few examples of drivers behind cost-critical metrics like energy consumption that need to be monitored in order to build a real-time picture of operations. Having this “big picture” overview is needed to enhance and accelerate decision making to improve quality, cut waste and optimize resources.

Double-digit productivity increases

Industry 4.0 and IIoT technologies provide the Big Picture. They offer a fresh opportunity to collect synchronised data and build a transparent foundry view to orchestrate all foundry processes to work in harmony.

Add machine learning and data analytics tools into the mix and it’s possible to manage machine performance in real time while driving constant improvement in areas like predictive maintenance, remote diagnostics and production planning – and so advance the key variables of productivity, quality and resource consumption for real bottom-line gains. In fact, consultants McKinsey report a foundry-wide digital view can deliver double-digit productivity increases.

Monitizer - Turn your data into value

At Norican we have this covered. With NoriGate technology and Monitizer cloud-based solutions, real time data from every element of your aluminium operations (whether from a single foundry or a network of sites) can be centrally analysed and measured against KPIs set by you, from any location.

In other words, the right people will have the right information they need to make the right decisions at any given moment.

 

With every stage of the aluminium die casting process covered,
we’ll make sure you really can have it all, whatever the challenge.

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