February 19, 2024

IoT IN THE DIE CASTING INDUSTRY: TOWARDS A MORE EFFICIENT AND CONNECTED 5.0 FUTURE

The Internet of Things (IoT) is revolutionising the industrial landscape, offering new opportunities to improve the efficiency, productivity and safety of production processes. In the die casting industry, the IoT represents a significant step towards creating smart, connected foundries that can adapt in real time to changing market needs.

How can the IoT be applied to the die casting industry?

The applications of IoT in this industry are many and varied. Here are some examples:

  • Real-time monitoring of process parameters: Smart sensors can monitor critical parameters such as metal temperature, injection pressure and mould filling speed in real time. The collected data is transmitted to a centralised system for analysis and visualisation, allowing precise process control and early identification of any anomalies.
  • Predictive maintenance: Analysis of the data collected by the sensors can be used to predict machine failures and malfunctions, allowing predictive maintenance to be planned and downtime to be minimised.
  • Remote machine control: Die-casting presses can be controlled remotely via connected devices, allowing greater flexibility and productivity.
  • Production process optimisation: Analysis of production data can help optimise the production process, identifying areas of inefficiency and suggesting solutions to improve efficiency.
  • Product traceability: IoT can be used to track the production of each individual part, ensuring product traceability and regulatory compliance.

What are the benefits of IoT for the die casting industry?

The implementation of IoT in the die casting industry can lead to a number of significant benefits, including:

  • Improved production efficiency: Data analysis and real-time control of process parameters can reduce cycle times, increase production and improve product quality.
  • Cost reduction: Predictive maintenance and failure prevention can reduce maintenance and repair costs.
  • Increased safety: Real-time monitoring of process parameters can help prevent accidents and work-related injuries.
  • Improved flexibility and adaptability: Smart foundries can quickly adapt to changing market needs, producing smaller, customised production batches.
  • Greater transparency and control: Analysis of production data provides greater visibility and control of the production process.

What are the challenges?

The implementation of IoT in the die-casting industry, as in all companies entering Industry 4.0, presents some challenges, including:

  • Information security: Data security and the protection of industrial networks are critical aspects that must be adequately taken into account.
  • Skills and training: Staff must be properly trained to use and manage the new IoT technologies.
  • Integration with existing systems: The IoT must be integrated with existing production systems to ensure efficient and secure data flow.

The IoT represents an unmissable opportunity for the die-casting industry to improve efficiency, productivity and process safety. The challenges are not insurmountable and, with proper investment and strategic planning, foundries can benefit greatly from this revolutionary technology. The die casting industry is poised to become part of the fifth industrial revolution and IoT is the key to a more efficient, connected and sustainable future.
In addition to the above, the use of IoT in the die casting industry can lead to:

  • Better collaboration between different departments in the foundry: IoT can facilitate communication and collaboration between different departments in the foundry, from design to production to maintenance.
  • Development of new business models: IoT can enable new business models, such as servitisation, that offer customers a complete production service.
    Of course, all this requires cultural change, development of new skills, investment in new technologies.

The first step is to have efficient die-casting machines for your sector. If your company’s goal is to be competitive in the market, ask AGRATI AEE’s sales engineers for advice.