DISA is now offering an automatic filter setting feature for its DISAMATIC D3. The PLC-controlled, robot-monitored unit autonomously places filters into any uncored mould produced on a DISAMATIC D3, thereby removing the highly repetitive task of setting filters manually.
The Automatic Filter Setter (AFS) ensures precise and efficient filter setting at a speed of up to 555 moulds per hour, boosting production capacity, quality and safety, while freeing up experienced operators for value-added work.
Increasing production, improving quality
The AFS is released in two versions: a semi-automatic and a fully-automatic version. Both versions enable an instant increase in production of 70 moulds per hour for uncored jobs, allowing foundries to utilise the full DISAMATIC D3 production capacity of up to 555 moulds per hour. In addition to this capacity increase, the fully automatic solution can work unsupervised for up to two hours, freeing up valuable resource.
The AFS also improves precision with a filter placing accuracy of 0.1 mm. This reduces the occurrence of loose sand, reduces scrap and further improves overall casting quality. DISA’s Global Product Manager Lars Hjelm explains: “When we commissioned the first DISAMATIC D3 at a pilot customer, the automatic filter setting feature turned out to be a bit of a game changer. The AFS was designed primarily to boost productivity by increasing production of uncored jobs with filters, but it also helps enhance casting quality and improves working conditions and overall safety.”
More time to innovate
Lars continues: “One of the most remarkable ‘side effects’ of using the AFS is that it unlocks foundry resources. In fact, the fully automated version frees up the man-hour equivalent of one full-time employee. This time can be used for other, more value-added tasks around the foundry, leveraging valuable resources to promote innovation and continuous improvement.”
Beyond productivity and resource efficiency, the AFS also has a profound impact on the working environment around the moulding line. The AFS coordinates are part of the pattern data, which means that once filters are fed into the automated solution, they are automatically transported to the pick-up position of the AFS and placed into the mould without manual intervention. This creates a safer working environment and a predictable, steady process.
Lars concludes: “The AFS is also really straightforward to operate and doesn’t require operators to have any specific robotics knowledge. Its controls are fully integrated with the DISAMATIC D3 control system, which again saves time and resources and prevents errors.”