Development of Blowhole Checker BC-1 (Cast Product Defect Inspection Device) Shortens Inspection Time by Over 50% and Delivers Higher Energy-Saving Performance

Chubu Electric Power Co., Inc. (President: Satoru Katsuno; Head Office: Higashi-ku, Nagoya City; "Chubu Electric Power") and Nippon Crucible Co., Ltd. (Representative Director: Masashi Okubo; Headquarters: Shibuya-ku, Tokyo) will jointly develop the Blowhole Checker BC-1 ("BC-1"), a defect inspection device for cast products, and begin accepting orders on April 01.

In the process of casting automobile components and other parts, casting technology (aluminum die casting) is used to inject molten aluminum alloy at high velocity and pressure into a precision mold and thereby form a product instantaneously.

When molten aluminum alloy is injected into the mold, air or other gases may become enmeshed in the melt. If these bubbles remain during the casting process, a cavity ("blowhole") forms inside the product, resulting in a decrease in strength or other defect.

Consequently, during the process of inspecting samples, products are heated to a temperature at which they soften (approx. 530 - 560°C). This expands any air trapped inside the product, causing the product surface to distend, and the product quality is determined based upon the degree of distention.

Conventional inspections employ a method that circulates hot air within the device to heat up the product, but this requires heating for between 20 and 30 minutes. A shorter time has been sought to enhance productivity.

The BC-1 utilizes an approximately1,250°C mid-infrared heater, which is suitable for metal heating, to directly heat the product. Together with its optimal temperature control program, the BC-1 provides inspection times that are more than 50% shorter than conventional devices.

In addition, because of its quick startup time and direct product heating, it achieves greater energy-savings than conventional devices.

The BC-1 is equipped with a contact temperature sensor that directly measures the product's temperature, giving it the capability to inspect items at the precise temperature.

The BC-1 will be offered mainly to customers with transportation machinery. Chubu Electric Power and Nippon Crucible Co., Ltd. will support our customers' efforts to enhance productivity with packages comprising everything from manufacturing technology to product quality control.

[BC-1's Key Features]

• Shorter Inspection Time

A mid-infrared heater set at approximately 1,250°C, suitable for metal heating, is used to directly heat the product. Together with the optimal temperature control program, the BC-1 provides inspection times that are over 50% shorter than conventional devices.

(Conventional-type (hot air circulation): approx. 20-30 minutes ＝> BC-1 (mid-infrared heater): approx. 10 minutes (see note))

• High Energy Savings Performance

Because of its quick startup time and direct product heating, the BC-1 achieves greater energy-savings than conventional devices (approx. 0.5 - 1 kWh (see note)/inspection).

(Note) Heating time and power consumption vary depending on product material quality, size and weight.

[Basic Specifications & External Appearance]

Power source & maximum current	AC200V　3Φ3W　50Hz/60Hz　100A
Heater output	16 kW (carbon heater: 2 kW/heater × 8 heaters)
Compressed air	100 L/min use (0.5 MPa or greater)
Unit dimensions	Furnace body: W775 mm × D475 mm × H1,800 mm Control panel: W800 mm × D300 mm × H1,800 mm Installation space: W2,500 mm × D1,000 mm
Unit weight	260 kg (furnace body), 130 kg (control panel)
Inspectable products (maximum)	Dimensions: Φ150 mm × H80 mm Weight: approx. 700 g