Siemens, Toyota Partner for AI Die Casting Solution

Toyota Industries Corporation and Siemens worked together to develop artificial intelligence (AI) that can predict product abnormalities in aluminum die casting, a key process in automotive air conditioning compressor production.

The development relies on the AI application in Industrial Edge, the Siemens edge-computing platform for industry. Toyota aims to incorporate this development into its production plants in Japan and overseas. Siemens hopes that more businesses in the manufacturing industry will adopt digitalization and automation solutions, such as Industrial Edge.

Siemens reports that the die casting process is challenging to manage due to a range of constantly changing production conditions, such as variations in the molten aluminum temperature or the injection rate. Sometimes, the parts require secondary processing to handle abnormalities and maintain high quality standards.

During development, the two companies used a Siemens Simatic S7-1500 controller to gather approximately 40,000 data points per die casting shot at the model line and then analyzed the data using AI technology. They succeeded in preventing defects and improving quality by monitoring the production status in real time and predicting equipment abnormalities that would lead to quality issues. Production data was processed by the defect prediction AI on Industrial Edge, enabling instant analysis on production conditions at the time of a shot and assessment of the part quality immediately after the casting.

“It is significant that Toyota Industries Corporation has successfully implemented AI technology and achieved outcomes in the die casting process, which is where important compressor parts are produced. I am also proud that we have contributed to the practical use of Industrial Edge, the Siemens edge-computing platform for industry,” said Yuji Ishizaki, senior executive officer, member of the board and general manager of compressor division, Toyota Industries Corporation. “We will continue to offer new value for customers and to pursue even better working methods by embracing the use of advanced digital technologies in the production field.”