Factsheet: Innovation and Quality: Data Integration in Fonderia di Torbole's Production Process

FactSheet Innovation and Quality: Data Integration in Fonderia di Torbole’s Production Process www.alchimia-project.eu.eu Driving Excellence Data Integration for Innovation and Quality Fonderia di Torbole continues to strengthen its commitment to manufacturing excellence and technological innovation by integrating sophisticated data monitoring throughout the entire production cycle. Today, the company verifies numerous parameters at the beginning of the process (input data) and at the end on the physical part of the product (output data), ensuring rigorous and timely quality control of the brake discs and brake drums produced. One of the main steps in the production process begins with “melting and mold casting.” The liquid cast iron is obtained by melting, in optimal proportions, pig iron, steel scrap, our return and ferroalloys. Combustion, generated by coke and air (possibly enriched with oxygen), occurs inside a long-campaign hot-blast cupola with a melting capacity of 30 tons/hour. Once produced, the liquid cast iron is channeled into holding electric furnaces (receiver) and then transported via ladle forklift to pouring furnaces, which feed the green sand molding lines. Enhancing Quality and Efficiency at Fonderia di Torbole From Melting to Quality Control: A Dual-Track Process 02 03 Following mold casting, the castings undergo a series of processes: after shakeout, the castings are transported to the shot blasting area and then to the testing area, where operators perform quality tests. The finishing of the pieces is completed through the removal of casting burrs using grinding and automatic deburring machines. During this phase, key input data are collected, such as:: These parameters, monitored on an hourly basis, are essential for setting up and optimizing the melting process. Melting and mold casting The “raw product testing” takes place in our metallurgical laboratory, where various tests are conducted, from verifying mechanical properties to hardness tests, and analyzing natural frequencies. Only in this final phase, which takes 3-5 hours after production, is it possible to determine the products’ compliance with the required quality standards according to customer requirements. - Amount of inoculant - Measurement of chemical composition (%) - Temperatures - Thermal analysis properties of liquid cast iron in various furnaces Raw and product testing 04 05 Alchimia Artificial Intelligence at the Service of Production To further improve the efficiency and quality of the production process, Fonderia di Torbole has decided to integrate the “Alchimia” system, based on sophisticated artificial intelligence software. This tool is designed to: The main advantage of this integration lies in the ability to predict the final result exante, eliminating the 3-5 hour wait for ex-post analysis and enabling timely intervention in case of anomalies. Reduction of scrap material a decrease of over 10% is expected. 01 Reduction of energy consumption and CO₂ emissions a decrease of over 3% is expected, contributing to making the production process more sustainable.. 02 Optimization of production costs the reduction of scrap consequently leads to lower production costs and an increase in production capacity. The technology represents a strategic investment for the future..03 with particular attention to defects such as porosity, the presence of cementite and natural frequencies; the data collected from chemical and thermal analyses performed on line furnaces; between input data (amount of inoculant, chemical composition, temperatures, and thermal properties) and output data related to the quality of the final product. Expected Results and Benefits for the Industry The adoption of the Alchimia system translates into tangible benefits: - Predict the quality of the raw piece, - Analyze in real-time - Identify stronger correlations 06 07 FONDERIA DI TORBOLE S.R.L. Via Travagliato 18 Torbole Casaglia (BS) Italy +39 030 215 99 01 [email protected] Linkedin: fonderia-di-torbole Website: www.ef-group.it/fonderia-di-torbole Conclusions Fonderia di Torbole confirms its state of the art technology in the metallurgy sector, thanks to a production process that synergistically integrates input and output data to ensure the highest product quality. The innovation introduced by the Alchimia system, with its predictive capabilities based on artificial intelligence, represents a significant step forward in the control and optimization of production processes. This integration not only allows for the anticipation of potential defects but also offers a significant contribution in terms of environmental sustainability and cost reduction. A choice that further strengthens Fonderia di Torbole position as one of the benchmark in the cast iron component manufacturing sector. In an increasingly competitive and sustainability-focused market, the adoption of innovative technologies like Alchimia not only improves product quality but also paves the way for a future where production efficiency and environmental respect go hand in hand. 08 www.alchimia-project.eu.eu