A data driven approach to shell manufacturing

Data-driven decision-making plays a crucial role in optimising investment casting processes. As a leading manufacturer of shellroom equipment, we understand how important it is for shellroom operators to use data to explore correlations between process parameters and defects to then optimise the shell-making process. Data can be retrieved from machine learning models, data visualisation tools, and casting simulation software. The combination of these tools reduces trial and error and improves investment casting efficiency by leveraging proven performance.

A number of key parameters must be monitored during the shell manufacturing process; wax pattern design and geometry, shell coating material, coating thickness and uniformity, and environmental conditions. Using process management software in conjunction with shellroom equipment can provide critical data on such parameters. This is why we have designed an IC-Crystal shell management system to provide our customers with the data they need for process optimisation in shell manufacturing.

IC-Crystal is the control at the heart of the shell manufacturing system. IC-Crystal supervises the process from the wax pattern arriving in the shellroom, until completion of the shell. IC-Crystal provides real-time monitoring and long-term analysis of process data, environmental conditions, shellroom system performance, and equipment service alerts. All of which is accessed through a user-friendly touchscreen monitor.

We have designed IC-Crystal to provide shellroom operatives with a clear understanding of processes to allow easy adaptation. IC-Crystal can operate with a single automated cell and complex multi-cell shellroom systems; with the ability to monitor several robots simultaneously. Key Process Variable (KPV) data is monitored of individual shells for quality assurance. Some examples of the recorded KPV data include individual shell weight, temperature, pH, viscosity, slurry level, tank rotation, etc.

All of this is part of Industry 4.0 made possible with connectivity, data, and computational power, analytics and intelligence, human-machine interaction, and advanced engineering. This is only part of the equation. To implement Industry 4.0 with confidence, companies must ensure that their workforce is equipped and trained in the necessary tools. To support our customers in implementing IC-Crystal into the shellroom operation, we offer a comprehensive training program in one of our fully functional training centres. This course offers guidance on how best to use our IC-series robot systems, and how to operate IC-Crystal to store data, monitor processes, and retrieve historical data for a process review.  IC-Crystal provides reliable, dedicated, intelligent system control, 24 hours a day, every day.

About VA Technology
VA Technology is a supplier of complete shellroom systems and equipment. The company has extensive experience in the design, manufacture, installation, and service of shell manufacturing equipment throughout the investment casting industry. Contact us to find out more.