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EUREKA 2657: Moulding on Demand - New flexible, eco efficient system for JIT Moulding Production

Project LeaderAytul Ercil
Project SupervisorAytul Ercil
Project Team
  • Aytul Ercil
  • Burak Borhan
  • Apurva Somani
Supporting Organizations
  • SCM ITIA (Italy)
  • Parallel Kinematics Machine (Switzerland)
  • IFPG (Germany)
  • Vistek (Turkey)
Project Budget19.21 milyon euro (SU budget: $ 62.010)

ContactAytul Ercil Send e-mail

Start Date2003.09.01
End Date2005.08.30
Project Description
The aim of this project Is to study, develop and produce a new flexible, eco-efficient system for JIT (Just-in-Time) moulding production. The first phase will make it possible to acquire the missing know-how needed to produce new, eco-efficient systems able to optimize the relation between the foundry structure and the environment/society. In the second phase the acquired know how in this M.O.D. project will make possible the study/development of an innovative and integrate system able to give the right answer in eco-efficient way at low cost and with high quality. The project aim is to realize the proposed system and apply it to the production plant. The eco-efficiency requirement will be achieved by the reusing and the recycling of foundry sand and the development of new processes with low environment impact. To design the mouldings, a real time collaboration environment will be developed, which will allow customers and foundry technicians to work together in real time. In order to respect the requirements of high flexibility/ quality, the production line will be equipped with: production planning system, which use massive simulations and shop floor information, automated cells which will be able to produce the models, using CAD output product/process control systems, integrated with the production, which will make possible the selection of faulty pieces and provide a feed-back signal to the production cell controllers for dynamic adaptation, and the new real-time management system:
a) vision system, which will be used to detect the possible fault items on the base of the vision in the models, cores and mouldings production phase. Moreover, it will use the CAD output to check their shape.
b) technological testing system, which will be used to test the mouldings
c) material testing system, above all to test automatically the cast iron before the casting.
This integrated quality control system will make it possible to drastically reduce the lead time and the no quality costs * highly automated handling system * automated forming cells * automated cells which will be able to trim the mouldings, using the CAD output. The computing/ communication system (hardware and software) that will be applied to advanced manufacturing process control and supervision, will combine high data flows, high performance computing (video analysis for quality inspection), real- time control managing an agile JIT production system.

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