The digitization of the ladle shows that Industry 4.0 and manual production are very much compatible with each other

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Foundry Corporate News

19. July 2023

The digitalisation of the Pouring Ladle will be an important issue in the foundry industry in the near future. Within a few months, Dr Eric Riedel, project manager at the Institute of Production Engineering and Quality Assurance at Otto von Guericke University Magdeburg, developed the prototype of a Pouring Ladle that can digitally record and link data (Pouring Ladle 4.0) to improve the quality of manual casting processes.

Pressemitteilung | Reading time: min

International Editor Diana, Engelmann

The idea arose in the course of digitalisation. Especially SMEs have difficulties with this issue, as digitisation and IT are very time-intensive and foundries often lack sufficient resources in this area. The number of manual work and process steps is still high, and efficiency potentials are not fully exploited. Fact is: digitalisation and AI are just at the beginning. In addition, there is a shortage of skilled personnel. Therefore, it was very important for Riedel to develop with the Pouring Ladle 4.0 a tool that improves efficiency, reduces waste, and offers - at the same time - direct added value to SMEs as well as to the single employee.

Significantly higher degree of reproducibility

Through real-time recording and visualisation of process-relevant measurement data, as well as through the compatibility of the Pouring Ladle 4.0 with mobile end devices and data glasses, employees are actively involved in the digitalised casting process. A traffic light system in the process monitoring also offers the possibility of approval or, in the event of discrepancies, direct intervention. At the same time, the Pouring Ladle 4.0 has the same handling as the conventional model. However, from an economic point of view, the digitalised ladle offers numerous advantages. "We achieve a significantly higher degree of reproducibility and can thus actively avoid scrap," Riedel states. "The prototype is currently designed for light metals, but the technology behind could also be used for iron casting, for example." As a result, the Pouring Ladle 4.0 can basically be used in many foundries with manual casting production worldwide. Depending on the size of the company, the implementation takes only a few days.

They were instrumental in the development of the digitized casting ladle: Ingo Horn (left in picture), Managing Director of ENA-Elektrotechnologien und Anlagenbau GmbH and Dr.-Ing. Eric Riedel, Project Manager from the Institute of Production Engineering and Quality Assurance at Otto von Guericke University Magdeburg.

"The target of the project was the development of a tool that enables SMEs an easy entry into digitalisation and Industry 4.0 whereby the added value is immediately recognisable."- Dr.-Ing. Eric Riedel

"The target of the project was to develop a tool that enables SMEs an easy entry into digitalisation and Industry 4.0 whereby the added value is immediately recognisable and can be easily integrated into the existing process. In my opinion, the Pouring Ladle 4.0 reflects exactly that," states Riedel about the motivation behind his project. In application, the Pouring Ladle 4.0 combines several useful features such as real-time transmission of measurement data, an interface with miniature plug connection and thus the use of established thermocouples, inductive charging with rechargeable battery and a modular design with replaceable wear module.

Conclusion: According to Riedel, the Pouring Ladle 4.0 shows that Industry 4.0 and manual casting production are very compatible with each other, whereby the human resource is well integrated in this development.