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

CASE STUDY

Propeller design by means of multiobjective optimization: CP propeller test case

Validatipon of the results by means of an experimental campaign carried out at Genoa University Cavitation Tunnel

Modern propeller requirements involve many different characteristics, not limiting only to maximum efficiency, but considering also propeller cavitating behavior and, more and more, its side effects, in terms of radiated noise and pressure pulses.

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Controlled Floater for Marine Pipeline Towing

A system to simplify the towing and laying down of marine pipelines in shallow water fields

A developer of innovative equipment designed a system to simplify the towing and laying down of marine pipelines in shallow water fields.

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Our Expertise with smart ProdACTIVE

CASE STUDY

How to optimize an external gear pump in highly constrained conditions

Meeting the engineering challenge of increasing efficiency while reducing costs

In this technical case study, EnginSoft assists Casappa to further refine an already-optimized standard series pump for an electrical motor and generator

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Optimizing the Glass Clamping of a Pyrolytic Oven

An appreciable 30 to 40% decrease in stresses

The aim of this study was to find the best quality glass-clamping system, through parametric model optimization, for a new pyrolytic self-cleaning oven by Indesit.

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Multi-Objective Optimization of a Sailing Yacht Aluminum Mast

The optimal mast weight under specific structural strength requirements

The aim of this study was to reduce the weight of the world’s tallest aluminum mast for a new series of single mast sailing yachts manufactured by Perini Navi under the brand name Salute.

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