MUSIC Demonstrators

All the activities addressed during the 4 years of MUSIC Project are fully coherent with the strategic issues of the Call FoF-ICT-2011.7.1 “Smart Factories: Energy-aware, agile manufacturing and Customization – target outcome c).

In order to fully implement the new C&CS tool with the different monitoring devices in the production line and to prove its functionning, it's necessary to test it in short-run productions, well-representing all industrial sectors using the HPDC/PIM processes.

Targeted demonstrators have been selected and some estimations in terms of defects, scrape rates and recovery of lost value have already been made.

HPDC Demonstrator: AUDI SHOCK TOWER

This demonstrator is a thin walled die casting.
Such part is subject to different kinds of defects (distortion, air porosity, shrinkage porosity and inclusions), with a customary scrap rate of HPDC structure parts of 5-15%. Thanks to achievements of the MUSIC project the expected scrap rate will be reduced to 0.5-1.5%, thus creating a lost value of 375,000€/year per HPDC machine.

 

HPDC Demonstrator: RDS GEAR MOTOR HOUSING

This demonstrator is cover and housing with good mechanical resistance and adequate dimensional requirements. Such part is subject to different kinds of defects (lamination, cold shots, flash, incomplete casting) with a scrap customary rate of lamination and cold shots of 6-7%. Thanks to achievements of the MUSIC project the expected scrap rate will be reduced from 6-7% to 1-1,15% thus obtaining the creation of a lost value of 45.000€/year.

 

PIM Demonstrator: MAIER PLASTIC BAR

This demonstrator has to respect several aesthetic requirements.
Such part is subject to different kinds of defects (flash, weld/meld lines, flames, sink marks) , with a scrap rate of 5000 injected parts per mould. Thanks to achievements of the MUSIC project the expected scrap rate will be reduced from 5000 injected parts/ mould to 4500 injected parts/mould, thus obtaining a saving of a 10% of the overall costs, equal to 310.000€/year per 100 moulds (3.100€/mould).

 

PIM Demonstrator: RDS GLASSES

This demonstrator has to respect several aesthetic requirements.
Such part is subject to different kinds of defects (degradation of material, surface defects due to dust, parting line, deformation marks), with a customary scrap rate of lamination and cold shots of 6-7%. Thanks to achievements of the MUSIC project the expected scrap rate will be reduced from 6-7% to 1% thus obtaining the creation of a lost value of 15.000€/year.