CASTRIGHT II™ Automated Casting Control

Almex’s CASTRIGHT II™ System Automation integrates all the peripheral equipments and processes involved in the casting operation. The system integrates Allen and Bradley PLC’s with custom designed HMI interface screens providing a very user friendly and intuitive layout. Our control systems boast multi-language support for worldwide compatibility. All control cabinets are equipped with air-conditioners and heater elements for cabinet temperature control and optimum performance.

CASTRIGHT II™ regulates the entire casting operation. Complete hardware and software for casting control system are provided:
• Operators control console that includes critical push buttons, switches, displays, indicator lights, warning lights and warning signal devices, industrial computer, HMI display screen, and keyboard.
• Programmable Logic Controller, I/O and communication modules
• HMI software, programming and screens
• PLC programming for control of cast speed, mold water flow rate, and grain refiner speed for the casting process based on multiple “recipe” databases. Programming includes pre-cast checks and permissive monitoring and alarms.
• Complete Detailed Program Documentation including description of program logic, algorithms, and values limits for process parameters, warning and alarm conditions.
• Casting machine interlocks and fail safe design

The CASTRIGHT II™ SCADA (Supervisory Control and Data Acquisition System) system consists of local and remote system monitoring and control capability. The system architecture is designed in three tiers and each layer is password protected. The special features of the SCADA package are:

• Complete reporting is available for each drop.
• Heat information archival capability
• Remote troubleshooting and PLC program updating (No site visits required for programming personnel)
• All data is accessible in continuous form or as function of each heat
• Heat print outs have capability for as many parametric charting and printing as the customer would like to configure.
• Ethernet based data sharing and /or PCAnywhere™ assisted Log-ins permitting real time inspection of casting data from any global location and historical analysis of casting parameters.
• Plant intranet accessibility for access at plant office locations.
• The system is ideally suited for Production level cast-houses where casting data recording is a prerequisite for end users (aerospace, transportation etc.).
• Either in house or remote server capability for data storage and manipulation.
• Single system will be configured for three (3) casting lines.
• The system can further be configured for additional applications as an option including:
- Store video shots of the casting operation if customer supplied digital CCTV cameras are used in the casthouse.
- Automatically send text messages to the cell phone of key personnel if a predefined level of alarm occurs during casting.
- Capturing data from other casting line equipment if data is being transferred through the same Ethernet line.

SCADA will give your company an enormous advantage.
• Ease of Quality Audits by Buyer’s customers
• Immediate information archival
• Remote Troubleshooting and PLC program change downloading