The production line is designed for metal casting using gasifiable foam patterns (Lost Foam Casting — LFC process).
Polystyrene models placed in quartz sand are filled with molten metal, which vaporizes the foam and takes its place.
The resulting gases are extracted through the sand layer by a vacuum system.
Molding of the pattern with sand is performed on a programmable vibration table with adjustable process recipes, which eliminates human influence on molding quality. The molding system produces up to 20 molds per hour, maintaining continuous vacuum in the flasks until the castings cool down.
The line operates in a closed sand circulation cycle — the sand is sieved, dedusted, cooled, and returned to the process, ensuring zero-waste operation.
The automation system must operate the line according to the process algorithm while maintaining interlocks and safety protections (ESD).
Basic control and status indication are provided through a push-button operator panel, while configuration of process parameters, vibration table recipes, and extended visualization are available on a graphic HMI panel.
The system supports a multilingual interface: Georgian, English and Russian.
The control system is implemented using a Mitsubishi Electric MELSEC FX3U controller and a 10-inch HMI panel. All process parameters and settings are displayed directly on the operator panel.
The system monitors equipment operation, executes automated sequences according to the process algorithm, detects abnormal conditions, and prevents operator errors.
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