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DISA MAC mold accuracy controller

High-Precision Measuring for Mold Alignment

April 16, 2018
Laser-based device captures mold-related mismatch, mold gaps, mold steps, and parallelism before pouring.

DISA is launching the Mould Accuracy Controller, or DISA MAC, a high-precision measuring device that captures mold-related mismatch, mold gaps, mold steps, and parallelism for each mold before pouring. The DISA MAC helps to identify issues around mold alignment before they become a problem — meaning, before they result in unnecessary rework or scrapping of any castings.

The DISA MAC device consists of a bridge-like scanning bracket that is mounted across the mold string between the molding machine and the pouring unit. This bracket is equipped with laser sensors that scan continuously along the mold string, tracing specifically designed impressions on each mold.

Customized software uses these readings to calculate critical alignment parameters and identify issues according to customer pre-set limits. A warning light on top of the bracket alerts the operator to any issues via a simple traffic light system.

“The DISA MAC allows foundries to keep a constant eye on the mold string, collecting key dimensional data and flagging issues before it’s too late,” according to Kasper Paw Madsen, global product manager digital solutions. “The DISA MAC ensures that only good, perfectly aligned molds are poured.

“The potential reduction in rework and scrap as well as the improvement in casting precision is significant,” Madsen added. “It’s a simple device, but thanks to the software behind it, it could well revolutionize the casting process for our customers.”

In addition to the warning light on top of the DISA MAC bracket, operators can access more detailed DISA MAC data at the operator panel of the molding machine, viewing real-time data in dashboard, table or graph views.

For deeper analysis of historical DISA MAC data, the system includes the DISA Foundry Cockpit, a new data platform for foundries.

“There’s great potential in the dimensional data captured by the DISA MAC, that can be analyzed over time and correlated with other data, to get an ever deeper understanding of your process,” Madsen continued. “The DISA Foundry Cockpit creates the foundation for this type of analysis, not just for DISA MAC data, but for any type of foundry process data. Watch this space.”

The DISA MAC is available as either an option for all new DISAMATIC D3 molding lines or as retrofits to existing DISAMATIC D3 equipment.
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