SinterCast System 4000 Plus

The fully automated System 4000 Plus provides a flexible, robust and accurate hardware and software platform that enables SinterCast customers to independently control CGI series production and product development. The System 4000 Plus is comprised of individual hardware modules that can be configured to suit the layout, process flow and production volume of any foundry, both for ladle production and pouring furnaces. In addition to the automatic feedforward correction provided by the basic System 4000, the System 4000 Plus also provides automatic feedback control of the initial base treatment process.

Based on the automatic input of base iron chemistry, ladle weight, iron temperature, and the historical SinterCast results, the System 4000 Plus calculates and adds the optimal amount of magnesium and inoculant cored wire in the initial base treatment. Automated base treatment prior to the measure-and-correct process control strategy enables foundries to reduce the variation of the base treatment process, thereby preventing operator error and improving the efficiency and productivity of the CGI series production process. The basic configuration of the System 4000 Plus consists of two Sampling Modules to obtain the thermalanalysis samples, an Operator Control Module for data display and operator interaction, a Power Supply, two separate network-linked wirefeeders for base treatment and correction, and a Peripheral Input Module for the collection of input data such as chemistry, ladle weight and iron temperature for base treatment and post-treatment data such as pouring temperature and time. This configuration provides sampling capacity for approximately 15 ladles per hour. Additional hardware can be added to accommodate each foundry layout and production throughput.

System 4000 Plus Features

• Accuracy: Proven, high resolution SinterCast thermal analysis.
• Automation: Automatic base treatment by cored wire, based on automated input of ladle weight, temperature and historical SinterCast analysis results from previous ladles.
• Process Control: Automatic wirefeeding for the correction of magnesium and inoculation for each ladle.
• User-Friendliness: Display of magnesium, inoculant and carbon equivalent results as histogram run-charts with all information in the local language.
• Process Database: Collection of melting and pouring data into a single database, including all System 4000 thermal analysis results and process data for advanced traceability.
• Consistency: Re-useable Thermocouple Pair can perform up to 250 measurements, providing accuracy and traceability.
• Efficiency Benchmarking: Production results compiled every month and delivered to each customer with analysis and process improvement input from SinterCast engineers.
• Independent Control: Supervisor-level access to process parameters, directly at the Supervisor’s desktop computer.
• Robust: Rugged Windows 10 IoT embedded operating system and hardware proven in the foundry environment.
• Remote Support: VPN access by SinterCast for technical support and maintenance.
• Flexible: Pallet mounted, or individually floor-mounted, to suit any foundry layout.
• Remote Access: Real-time result viewing on any internet-connected device.

System 4000 Plus Specifications