Trim Press Enhances Casting Cleaning Speed, Accuracy.

With the goal of increasing foundry cleaning roam throughput and worker safety, the casting trim presses from Modern Technologies and Machinery, Inc., Anniston, Alabama, incorporate a number of design features. Utilizing either robotic or manual handling of cast components, the automatic trim presses feature the following: dimensional control of the castings; accurate casting trimming; defect detection; system management and maintenance software; and ultrasonic non-destructive testing.

* Dimensional control of castings--After the casting has been placed in a cradle by either a robot or worker, the dimensional laser gauging system ensures the casting meets its dimensional requirements. This step ensures that castings out-of-dimension will not enter the trim press, thus ensuring continued system throughput. The non-contact laser gauging eliminates the need for constant calibration and can be performed with little or no training. The absence of contact points makes the laser gauge far exceed the life of conventional gauges. Laser gauging also offers a high degree of immunity to dirt contamination.

* Accurate trimming--After being dimensionally verified, the casting is enveloped by the Posi-clamp, which holds it rigid (to ensure an accurate trim) as it passes through the trim die. In addition, the trim press utilizes the manufacturer's Intelli-die, a flexible die that compensates for its own swelling and shrinkage thus reducing the chance of an inaccurate trim. Presses can handle any size casting.

* Defect detection--As a tool for external casting defect detection, the vision system compares a real-image of the casting to a sample defect-free image looking for defects. This system uses DVT Technology, which uses image sensors that can inspect fast-moving manufactured goods with accuracy. Mini memory processors accept, interpret and form specification conclusions in milliseconds.

* Management and maintenance tools--The Tracking On-line Production Software (TOPS) and Remote Automation Manager (RAM) provide the foundry with extensive monitoring and troubleshooting of the trim press systems. TOPS is an extensive foundry data acquisition software package designed to link all aspects of operations from machine operator to the foundry CEO's desk to the customer's desk. Maintenance can access the manufacturer's engineers and support personnel and troubleshoot while accessing identical data simultaneously. RAM is a state-of-the-art tool kit designed to allow the manufacturer's engineers to work from any location. Any machine outfitted with this kit can be accessed using the Internet or dial-up connection, thus allowing full control over the equipment's electronics.

* Nondestructive Testing (NDT)--As the final step in the process, the trim presses can be outfitted with ultrasonic flaw detection NDT. Testing can be accomplished during processing of the casting, lessening operator responsibility and increases processing speed though the cell.