Siemens and Toyota Industries have developed AI to predict product defects in aluminum casting

2021: Development of AI to predict product defects in aluminum casting

Siemens and Toyota Industries Corporation jointly developed artificial intelligence (AI), capable of predicting product defects in aluminum casting. This step will help improve the quality of parts for compressors of automotive air conditioning systems. This became known on May 20, 2021.

The solution improves quality and performance through the application of AI based on Industrial Edge industrial peripheral computing platform from Siemens. In the future, it is planned to be implemented at the company's enterprises both in Japan and abroad.

Casting is a very complex process in control due to the constant change in a number of production factors, for example, the ratio of temperatures or the injection rate of molten aluminum. Success depends on specialist experience, and sometimes parts require secondary processing to eliminate defects and ensure that they meet the highest quality standards.

To reduce the influence of the human factor in decision-making, the SIMATIC S7-1500 controller was used in the development. Using it, "big data" were collected in the total volume of approximately 40,000 points per casting cycle in the model series, and then these data were analyzed using AI technology. As a result, it was possible to avoid defects and improve the level of quality by monitoring the state of production in real time and automatically predicting equipment failures. Production data is processed by a special AI for predicting defects based on Industrial Edge, which allows you to instantly analyze information about production conditions after injection and evaluate the quality of the part immediately after the completion of the casting process. This series of AI technologies is designed to increase productivity and quality, as well as optimize the performance of operators.

Aluminum casting is a high-speed casting process in which molten aluminum is injected into a mold under high pressure. The procedure is ideal for the careful manufacture of metal cast parts, for which high dimensional accuracy is important, and therefore is often used for the production of auto parts that require high quality and reliability.

Siemens's mission was to help with operational improvements through the Industrial Edge platform, while Toyota Industries Corporation focused on improving quality and performance. As a result, partners were able to confirm the concept on which they worked for two years, as well as achieve high results. Based on them, both companies will continue to develop technological progress in order to be able to offer even better products to their customers around the world.

I am pleased to be able to collaborate with Toyota Industries Corporation in working on digital transformation and together create a future, "says Rainer Brem, head of the Automation of Discrete Production division of Siemens AG. - We will continue to develop and propose solutions using the latest technologies for various industries and contribute to the optimization of sustainable production.

Toyota Industries has introduced AI technology and has achieved results in the casting of important compressor parts. For us, this is a serious achievement. I am also proud that we have contributed to the practical application of the industrial platform of peripheral computing Siemens Industrial Edge, "comments Yuji Ishizaki, top manager, board member and chief executive officer of the compressor division of Toyota Industries Corporation. - We will continue to strive for even better methods of working with advanced digital technologies in production.