Hen Foundry

Hen Foundry
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Optimization of the charge make-up to minimize costs Interactive process control during weighing of raw materials Alloy calculation after completion of the raw material type Flexible mixture management inventory management Interfaces to crane PLCs and scales Interface to dosing systems

Heat information Charge data Analysis management for thermal and chemical analyses Calculation of final adjustments to the melt composition Tracking of the tapping and transfer procedures Statistic evaluation of consumption and cost

Automatic transfer of process data or optional manual acquisition Interactive acknowledgement process Documentation of all interventions Flexible evaluation over longer periods of time Permanent link to the respective valid specifications (version tracking)

CSL: Statistical and regression analysis software

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In modern foundries, a large number of process variables must be monitored, controlled and documented.
The GIS software has a modular design, it collects, distributes and documents all relevant process and production data in a foundry. The collection of production data from our software in a central database allows for a continuous tracing of the casting process from the base material to the finished casting. It is the tool of choice for the foundry engineer to describe the relationships between process, structure and properties of cast products.
The configuration of the GIS is specially adapted to the foundry processes, to make the data collection as efficient as possible. For the data exchange with plant controllers and measuring devices, a variety of interface modules are available.
The data source can be accessed and recorded automatically or manually and varies from raw material analysis, melting, treatment and pouring protocol, Thermal analysis, spectrometer, C/S combustion analysis, sand laboratory, mechanical properties results, image analysis and finished part testing.
Through the central data-base, all process data is comfortably available to all users.
Based on the parts or material specifications, the compliance with the specifications is constantly controlled during production and any deviation is signalled with a colour marking.
The optimization of the process is facilitated by regression tools and interdependencies of certain process parameter can be easily calculated and verified.
The GIS-Base Module provides comfortable access to the results of thermal analysis, temperature measurement and laboratory analyses in tabular and graphic mode within the network. Histogram charts and a regression function for controlling the %C and %Si determination via thermal analysis complete the set of functions.
The specifications for materials, castings, raw materials and the system configuration are maintained in the GIS master data administration:
The master data will be stored in the data-base with a version tracking system, to ensure that changes to the specifications are recorded for documentation.
The GIS-Charge Calculator offers a customized charging process, adapted to the characteristics of your melting procedure.
The GIS – Melt Report is used for documentation and control of the melting process.
The process data can be automatically transferred to the SPC module to manage SPC control charts.
The results from the material tests at the laboratory can be made available in the GIS-Laboratory Data module.
The results from the material tests will be automatically collated to the corresponding production and analysis data, to allow an efficient record tracking and process evaluation.
Using the GIS SpectroImport module, the results of a spectrometer's chemical analysis can be automatically imported into the GIS database. The information is also matched to the respective furnace or production charge number following configurable criterions.
The spectrometers from the following suppliers can be connected:
Spectro, OBLF, Thermo Scientific ARL, Leco
Connection to other equipment supplier’s also possible, if requested.
The GIS can use several interface modules to connect to numerous peripheral systems in the foundry, such as:
In foundries, the monitoring and documentation of sand systems is becoming increasingly important. With the help of the moulding sand database you can comfortably manage the data of your sand laboratory.
The software can be flexibly adapted to the inspection scope of the moulding and core sand systems. For an optimal overview, the sampling points of all systems can be defined hierarchically structured in the system, standard and special test ranges can be created for each sampling point.
At the end of the analysis, the results can be retrieved from the database, printed as a report or sent by e-mail. Various presentation options are available for the evaluation of the results, e.g. the chronological course of one or more test values can be displayed in a user-definable diagram or a statistical evaluation can be carried out via the histogram module.
The Micr-O-Phase program is an image analysis specialized in cast iron that has been designed to quickly measure a large number of images in order to achieve a high level of statistical certainty.
The system evaluates any number of images per sample. Both mean values and analyses of the individual images are available.
With our OCC-PhaseCam with C-Mount adapter, older microscopes can also be retrofitted with the Micr-O-Phase image analysis system.
The implementation of customer-specific algorithms offers the possibility to transfer special evaluation methods into the program.
The data from the image analysis can be directly linked to the data from the process and are immediately available for evaluation.
Evaluation of cause/effect relation between process parameters and casting defects or properties.
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WBRC 1720 Valley View Drive Birmingham, AL 35209 (205) 322-6666
A Gray Media Group, Inc. Station - © 2002-2022 Gray Television, Inc.
More stories to check out before you go
BIRMINGHAM, Ala. (WBRC) - Every morning, Chad Crutchfield goes into a 1,000 square foot hen house on The Foundry Farm in Cullman and collects hundreds of eggs.
“You wake up in the morning you feed them and water them a few hours later they start laying eggs. About 250 eggs a day,” he says.
The new hen house has been in operation a month now, and Foundry Ministries CEO Micah Andrews says it is already offering new options for the men in the recovery program at The Foundry Farm.
“Employment readiness and employment training has been a part of the foundry process for two decades so this adds a unique element for The Foundry Farm that we don’t experience at other locations. Not only is it a real tangible skill these guys are learning it enhances that employment educational process,” says Andrews. “It creates an opportunity for us to teach from beginning to end the poultry industry to men that are coming to us for recovery services so they can have a new skill set when they leave the foundry farm.”
Men in rehabilitation program at The Foundry Farm are in charge of everything from caring for the hens to collecting and processing the eggs.
“This is perfect for learning experience it’s just wonderful. It is a small enough operation where you can really train somebody and not have the bulk of eggs and chicken to take care of,” says Crutchfield.
From the building to the hens, everything was donated by community partners in Cullman.
Not only is the hen house project offering a new kind of job training for the man in the program, it is also saving The Foundry the $20,000 a year they normally spent on eggs.
“We are consuming all the eggs that are being laid, at all our locations in Bessemer, Birminghanm and in Cullman as part of our food services process,” says Andrews. “The neatest aspect for the men working with the hens is seeing a concept go to completion. They are seeing the hens that they are feeding and taking care of every day and the next morning they are eating the fruit of their labor.”
The program has only been running a month now, but Andrews says it’s already a success, and more men are wanting to sign up.
“It’s not the most glamorous job on the farm but they have really embraced it and it’s become one of those coveted positions,” says Andrews.
For Crutchfield, he grew up in a poultry farming family, and he says it’s setting him up for success.
“It’s a real blessing to come to a rehab facility and have a chicken house, I believe I am not here on accident, this is absolutely a meaningful experience for me,” says Crutchfield.
Copyright 2020 WBRC. All rights reserved.

WBRC 1720 Valley View Drive Birmingham, AL 35209 (205) 322-6666
A Gray Media Group, Inc. Station - © 2002-2022 Gray Television, Inc.
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