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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CASE STUDY

Cold Forging of a Silent Block Bush Steel Sleeve

Minimize physical prototypes and reduce waste, while reducing the lead time and overall production costs

The object of this study was simulating and optimizing the cold forging process for a silent block bush steel sleeve. A silent block bush is traditionally used in the linkage system of a car suspension, in railway carriages and in agricultural machinery.

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Our Expertise with smart ProdACTIVE

CASE STUDY

Steel Casting Optimization of a Gas Diffuser

An optimal gating and feeding system for the production of steel parts

The object of this study is a steel diffuser, which for obvious reasons needs to comply with very strict quality guidelines and industry regulations.

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Structural Analysis of the Planing Hull for the Permare Amer 116 Super Yacht

An efficient, fully integrated and optimized logic that consisted in the coupling of different software analysis tools

The main structure of the yacht is made of composite laminates with the presence of many composite reinforcements and bonded joints. We conducted a detailed structural analysis of the entire structure and verified the structural requirements.

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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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