GAPCast-en

GAPCast – “Hands Free Automation System”

The GAPCast automation software suite is composed of several modules, all of which have been tested in our laboratory before installation on site.

GAPCast is a fully automated process for managing all phases of vertical aluminium casting. The main role of the process control unit is to calculate, check and adjust all important parameters before and during the cast on the basis of the stored casting recipe. If the recipes are proven, from the “start phase” to the end the GAPCast system will control the machine automatically.

GAPCast_overview

 

Configuration Tools

Recipe Editor

The Recipe editor allows for management, comparison, modification, and creation of recipes for one or more casting machines. This software can be installed on several PCs connected to the company’s LAN. This allows anyone in charge of managing production to use and examine recipe data, meaning they can optimise and analyse said data without leaving their offices. The recipes are organised by machine, process type and alloy. The recipe name is a concatenation of width, thickness, user parameters and a revision number.

A recipe consists of:

The curves generate the set points for the main regulation loops (table speed, distribution of water in the ingot moulds, metal level, etc.). These values depend on the ingot length as well as the alloy being cast. Points 8 and 9 are reserved for the end of the curve. For these two points, the x value is not the ingot length but the value before the total length of the ingot. For example, 50 mm means 50 mm before the set point of ingot length. After a recipe is modified, the programme automatically saves the modifications and creates a “Logbook” file in order to track modifications. The person editing a recipe can add comments to the logbook.

Write access is password-protected. Different permission levels are determined in collaboration with the customer.


 GAP Editor

The GAPEditor is installed directly on the PC for the casting machine. This software is used to configure and edit the following parameters:

Write access is password-protected. Different permission levels are determined in collaboration with the customer.


Acquisition Tools

GAPCast uses software from iba AG (Iba-System & Products). The “ibaPDA” programme is used for data acquisition, and “ibaAnalyser” is used for analysis. Data acquisition is divided into three types:

IBA

The following data can be recorded: