Traceability System of Sand Core in Casting Production with a Digital-Twin Core Rack

Abstract

In recent development of casting traceability, it has been noticed that many casting manufacturing processes that involve the use of sand cores often lack proper traceability back to the cores used in their production and the supporting production information. Most marking symbols applied to sand cores using existing marking methods not only exhibit unstable code readability but also pose critical risks to the surface quality of sand cores. In response, we developed and tested a digital-twin core rack aimed at transferring digital codes to sand cores without contact with their surfaces. By utilizing infrared sensors for real-time object detection, the core rack can transfer digital identical codes from the core-making machine to the core rack, and subsequently to the casting machine. This digital code encompasses all relevant process data of a sand core, from core making to de-coring. Moreover, the various sensors embedded in the core rack were designed to monitor air humidity, temperature, and vibration events during the transport and storage of the cores. These parameters are especially critical for maintaining the quality of inorganic sand cores. The study demonstrates the successful application of each component within this conceptual framework. Looking ahead, it is imperative to update the hardware of this concept to ensure its adaptation to the demanding conditions of an industrial environment.