Mhira3D: a history of innovation to revolutionise die casting

Attilio Chillemi

Traditional control methods were no longer in step with the technological evolution of the die casting sector, no longer able to meet the quality standards required by end customers such as, for example, the automotive industry.

Hence the idea of integrating vision, to go beyond the capabilities of the human eye in terms of resolution, speed and repeatability of the result and be able to intercept very small defects or even those outside the visible spectrum.

The first solutions concerned the production of good/reject selectors. But we did not stop at this: we have designed systems that are able to prevent rejects, allowing to intervene with preventive maintenance, to avoid wasting resources and time. 

How?

Thanks to the process monitoring and data tracking that our systems provide, in line with the requirements of Industry 4.0, communicating in real time with the operator and with all connected machinery.

The information collected allows us to understand what the problem depends on and which point of the production line is most affected. In addition, by analysing the trends, we can identify the presence of a discrepancy before a defective product is generated.

Attilio Chillemi

The custom approach was a choice dictated by experience. In the die casting sector, of which we have gained 360-degree knowledge over the years, each company has specific problems related to its particular production.

Trying to respond to these needs, tailor-made products were born, but also replicable and customisable systems, such as our Mhira3D. 

Attilio Chillemi

Exactly, Mhira3D checks the integrity and completeness of many types of part just extracted from the press, while it is in the robot gripper, through a 3D analysis. This allows repeatable checks, for example of the presence of the overflows.

Each side of the part is analysed without slowing down production and, above all, without contact. But the most recent success of our Research and Development department was equipping the system with a thermal imaging camera capable of performing thermal analysis of the process at the same time as the 3D analysis. 

Attilio Chillemi

The system operates a smart control of the die temperature variations at each shot. Mhira3D examines the thermographic map of the part at the end of each cycle; this is nothing but the mirror of what is happening in the die itself.

In this way the part tells us about the thermal variations of the die. Any anomalies and drifts, detectable by means of innovative algorithms, are thus intercepted to anticipate and prevent events such as machine downtime.

This complete and real-time monitoring is available to the operator, who can identify the areas in which overheating is occurring and intercept problems related to cooling and lubrication, such as clogging of the nozzles; the operator can also automate start-up by optimising the number of initial rejects, identify broken pins and detect burr formation.

Attilio Chillemi

From the scientific literature it is known that attention to thermal aspects plays a crucial role in production quality and above all in the optimisation of resources. Experience in the field confirms this: defects arising from thermal problems are often not immediately detectable, but, if not intercepted, emerge in the subsequent phases. 

Attilio Chillemi

Mhira3D has a simple and intuitive interface, designed to be easily used by the machine operator, the production manager, the quality control officer and so on. In fact, communicating through images is immediate and easily interpreted by everyone.

The system adapts very easily to the different dies that can be mounted on the press, both in terms of size and in the number of cavities. The actions it requires from the operator are minimal: it is sufficient to set the inspection areas, then the analysis is performed automatically.

In addition, Mhira3D is designed for use inside the foundry and is not affected by the typical conditions of this environment. 

Attilio Chillemi

When a company installs Mhira3D for the first time, it is our pleasure to organise a short training, differentiated for all company figures who will use the system. Although its use is simple and limited to a few operations, it is essential for us to ensure support and assistance in the initial phase.

Subsequently, the customer is not left alone: we ensure rapid response times and assistance, with on-site or remote interventions.

Attilio Chillemi

Mhira3D has been installed in many companies in Brescia and its province, but also in Turin, Emilia-Romagna and Friuli-Venezia Giulia.

As for abroad, we landed in the United States, Brazil, India and the Czech Republic. 

Attilio Chillemi

The next goal is to make Mhira3D capable of automatically acting on the lubrication and cooling systems to maintain optimal thermal levels. We will then continue with the study of new features: since the engine of our research is represented by technological innovation, the horizon of possibilities is very wide.

Attilio Chillemi

The road travelled up to now has required resources, precious collaborations and above all commitment and perseverance on the part of the whole Imago team for the development of this project.

Attilio Chillemi

Imago has designed two other devices, specific for the subsequent stages of the process: Anglerfish for checking part integrity after the trimming phase and Magpie for checking porosity and machining processes. All information about them is available on our website and we are always available for personalized advice.