smart ProdACTIVE

ICT platform to real-time QUALITY PREDICTION and OPTIMIZATION supported by TRAINED COGNITIVE MODE

The smart ProdACTIVE tool predicts the quality, energy and cost of the injection process in real-time, covering the 100% of products, and suggests the appropriate re-actions to adjust the process set-up and/or mechanism. It works in combination with the real time monitoring system (or Intelligent Sensor Network) to elaborate instantaneously the production data set with respect to quality/energy/cost prognosis. The client-server mechanism works in combination with the real time monitoring system (or Intelligent Sensor Network) to elaborate instantaneously the production data set with respect to quality/energy/cost prognosis. The client-server Connections, based on OPC_UA protocol that is accepted as Interface for Industry 4.0, are collecting all process data coming from all existing devices and active sensors in a centralized database.

A fundamental innovative characteristic of smart ProdACTIVE tool is the Cognitive predictive quality model integrating multi-resolution and multi-variate process data, monitored and gathered by an articulated network of sensors by means of the collection of distributed control system, advanced models linking process variables to specific defect generation mechanisms, new optimization tools and remote management of production by self-adaptive equipment. The final tool is a smart web application to visualize, share and communicate the significant data and to support the decision making with proper reactions in real-time (retrofit) based on the captured signals from the process and intelligent elaboration of data by the quality model.

smart ProdACTIVE is a product of EnginSoft SpA

smart ProdACTIVE

ICT platform to real-time QUALITY PREDICTION and OPTIMIZATION supported by TRAINED COGNITIVE MODE

MONITORING MODULE

Database

  1. Real-time acquisition DB
  2. Hystorical data storage

Sensors connectivity; Smart Data visualization Traceability

  1. Advanced sensors connection (Machine, Die, Thermocamera, ThermoUnit, etc., customized)
  2. Web Dataelaboration&visualization: charts, diagram, 3Dviewer… thresholds, alarms, apps

CONTROL MODULE

Cognitive data model

Re-Active optimization

  1. Cognitive quality model (product model and training methods); re-active optimization
  2. Web Data elaboration & visualization: charts, diagram, 3Dviewer… thresholds, alarms, apps

Energy and Cost model

  1. Energy consumption visualization
  2. Real-time cost visualization during production

Predictive maintenance

Machine and tooling monitoring and data-driven prediction of possible failure

Web-service

  1. Customized connection to MES/ERP
  2. Remote web connectivity and Apps
smart ProdACTIVE

Main product modules

Main Benefits

  Faster Delivery Times

  Real-time Monitoring Active

  Scrap Rate: the involved HPDC foundry is expecting for a 40% reduction in scrap rate

  Production: flexibility, stability and efficiency is generating 10% of no-quality-cost

  Quality Control: in good exploitation scenario the cost of quality control can decrease of 40%

  Energy: energy consumption will be reduced by 5-10%, due to scrap reduction and more production efficiency with reference to the single cast part

 

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Insights

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Advanced strategies for the flow field optimization of a medical device

How to use a hybrid method of CFD analysis for product optimization and performance improvement while reducing the computational effort and the time required to achieve the results

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Our Expertise with smart ProdACTIVE

CASE STUDY

High Pressure Die Casting Optimization of a Connecting Rod

A multi-objective engineering simulation study of the connecting rods manufacturing process

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Fluid Dynamics Optimization of Racing Engine Inlet Ducts at Aprilia Racing

Optimising racing engine inlet ducts using fluid dynamics

Racing engines are continuously evolved and fine-tuned to allow them to achieve extraordinary levels of performance, albeit with great complexity. However, MotoGP regulations restrict engine development by constraining some of the main design parameters.

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Lucid Motors boosts electric vehicle performance with modeFRONTIER

Performing multi-objective inverter cooling system optimization with modeFRONTIER

This brief article summarises how California-based electric car company, Lucid Motors, used the CAE application, ModeFRONTIER for performing Computational Fluid Dynamics (CFD)

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