Black Box: The Fully Autonomous Foundry Sand Testing Lab in a Box
- Versatile Technical Team
- Feb 1, 2023
- 5 min read
A Fully Autonomous Laboratory in a Box from |
Application
Black Box is a fully autonomous laboratory in a box for foundry sands, designed to deliver repeatable, operator-independent sand testing and digital traceability. It automates sample handling, sample preparation and selected sand tests to help foundries control sand quality, reduce variation between shifts, and respond faster to non-conformances.
Product Description
Black Box integrates an autonomous robotic system, sample preparation and weighing subsystems, configured test modules, and an iPad-based HMI into a single enclosed unit suitable for near-line or laboratory use. It provides guided operation, automated routines, self-cleaning functions, calibration support, fault recovery, and structured reporting so customers can obtain consistent sand quality data with minimal manual intervention.
Core Features:
1. Autonomous robotic system: automated handling of samples, prepared specimens, and routine actions
2. iPad-based HMI: guided workflows, live status, alarms, and user access control
3. End-to-end sample preparation: standardized preparation routines for consistent test-ready samples
4. Sample weighing and verification: logged weights linked to sample and batch identity
5. Configurable test suite: supports customer-selected foundry sand tests and reporting templates
6. Self-cleaning systems and routines: routine cleaning cycles to reduce cross-contamination and downtime
7. Sampling apparatus cleaning: cleaning prompts and logged cleaning cycles for sampling interfaces
8. Self calibration support: calibration status indication, reminders, and calibration logging
9. Fault recovery: safe-stop states, alarm guidance, and resume capability after recovery actions
10. Non-conformance alerts: configurable alerts for out-of-spec results and abnormal events
11. Digital traceability: time-stamped records for batch, sample ID, recipe, results, and alarms
12. Data export and connectivity: exportable reports and optional integration to plant QA/QMS systems
General Usage
Define the required test suite and recipe on the iPad HMI, associate the run with a batch/sample identity, and start the run. Black Box performs the configured preparation and testing sequence, presents results on the HMI, logs the run with full traceability, and supports report export and alerts as configured.
Technical Specifications
· Form factor: Enclosed autonomous laboratory unit suitable for on-line/ near-line or laboratory placement
· HMI: iPad/tablet -based interface with guided workflows, alarms, and event history
· Automation: Robotic sample handling with automated preparation, weighing, and test execution (as configured)
· Self-cleaning: Automated cleaning routines for preparation, handling and sampling interfaces
· Calibration: Calibration support functions with status indication and calibration logs
· Fault handling: Alarm notifications, safe states, and automated recovery workflow
· Data logging: Automatic logging of results, timestamps, sample/batch identity, and system events
· Connectivity: Network-enabled export options (configuration dependent)
· Utilities: Power and compressed air requirements as per ordered configuration
· Safety: Enclosed operation with interlocks and controlled access to automation zones
· Compliance: Documentation and traceability features supporting customer QA requirements
Scope of Supply
· Black Box autonomous laboratory main unit (enclosed)
· Autonomous robotic handling subsystem
· iPad/Tablet-based HMI with installed application
· Sample preparation subsystem (as configured)
· Sample weighing subsystem (as configured)
· Self-cleaning routines and cleaning interfaces
· Calibration support utilities and calibration logs
· Fault recovery and alarm handling functions
· Documentation pack (electronic): datasheet, instruction manual, maintenance and safety guidance
· Commissioning checklist and acceptance records (electronic)
Recommended Pre-requisite Equipment
· Stable placement location (floor) with adequate clearance for service access
· Electrical supply and earthing as per installation requirements
· Compressed air supply if applicable (as per ordered configuration)
· Network connectivity for report export and backups (recommended)
· Waste sand collection and disposal arrangement
· Site PPE and housekeeping tools per foundry policy (brush/vacuum as permitted)
Usage Instructions
Refer instruction manual
Consumables
· Approved cleaning materials for routine cleaning cycles (as specified)
· Replaceable wear parts exposed to sand abrasion (as applicable)
· Sample containers/liners and waste collection consumables (as configured)
· Calibration check accessories used for routine verification (as applicable)
Hazards
· Moving robotic mechanisms and pinch points within the automation zone
· Electrical hazards during servicing and maintenance activities
· Compressed air hazards if applicable
· Dust exposure from sand handling; follow site dust-control and PPE practices
· Manual handling hazards when loading consumables or removing waste containers
Precautions
1. Operate only with trained and authorized users; follow site safety policies and PPE requirements.
2. Keep access doors/panels closed during automatic operation; do not bypass interlocks or alarms.
3. Maintain housekeeping: keep the work area clean, and dispose of waste sand and used consumables routinely.
4. Use only approved consumables and cleaning materials to protect subsystems and measurement integrity.
5. Ensure calibration status is valid before critical testing and follow calibration prompts and records.
6. Follow lockout/tagout procedures for service activities as per site requirements.
Additional Past info:
Autonomous Laboratory for Foundry Sand
The BlackBox is a modular, "lab-in-a-box" solution designed for modern foundries. By automating the sampling and testing process, it removes human error and provides 24/7 digital oversight of your sand system.
1. Smart Connectivity & App Support
The system is built for a mobile-first world, allowing managers and operators to monitor laboratory status from anywhere on the plant floor.
iOS & Android Support: Native mobile apps for real-time alerts, live run-tracking, and remote data review.
Bluetooth Connectivity: Seamless, secure wireless pairing with nearby sensors and mobile devices for localized diagnostics.
iPad/Tablet-Based HMI: High-resolution primary interface for on-site batch selection and workflow management.
Cloud Sync: Optional automatic backup of test results to secure cloud storage for cross-plant benchmarking.
2. Technical Specifications
Category | Requirement |
Power Supply | Configurable (Global Standards) |
Compressed Air | 5 Bar Dry (Dew Point < -40°C) |
Data Ports | Ethernet (RJ45), Wi-Fi, Bluetooth 5.0 |
HMI | Apple iPad Pro (Industrial Grade Case) |
OS Compatibility | iOS 15+, Android 12+, Windows 11 (Export) |
3. Core Capabilities
Total Autonomy: Robotic handling of sample containers and specimens.
Precision Preparation: Standardized "recipes" ensure every sand sample is conditioned identically.
Integrated Weighing: Automatic weight verification for 100% audit-trail accuracy.
Self-Cleaning: Automated internal routines to prevent cross-contamination between batches.
Smart Recovery: AI-driven fault recovery allows the system to clear minor jams and resume without intervention.
4. Operational Workflow
Select: Choose your test suite via the iPad or Mobile App.
Load: Enable the sampling input (In-line or Manual).
Start: One-touch execution from your handheld device.
Monitor: View live progress bars and robotic state on your phone.
Analyze: Instant digital reports sent via Bluetooth or Network.
5. Scope of Supply
Main Unit: Robotic laboratory enclosure.
Control Hub: iPad HMI with pre-configured software.
Module Suite: Preparation, weighing, and testing modules. (As ordered)
Documentation: Digital manuals (accessible via QR code on the unit).
Tool Kit: Basic servicing tools and initial consumable pack.
6. Safety & Support
Hazards: Moving machinery, pinch points, and dust management (all handled via safety interlocks).
Maintenance: Automated prompts for consumable replacement and calibration.
Support: Remote diagnostics package and on-site commissioning available.
Ready to automate your foundry?
The tests offered to be done with the Black Box include but are not limited to,
Sieve analysis + Sieve cleaning
Strength tests: Compression as well as time-domain compression for no-bake
Active Clay test (along with analysis and conclusions)
Permeability
Moisture (By dry and weight method)
Gas evolution
Loss on ignition
Wet tensile strength
Hot distortion test
Compactability test
Acid demand value (ADV) + pH testing
Tensile Strength test
And the list goes on and on...
End users can choose which tests are important to them and at what time interval are the tests to be conducted. With right sampling attachments, samples for testing can either be taken automatically or can be manually fed to the system.
Black Box also undertakes as per requirements,
· Automatic sampling from process (Wherever possible and necessary)
· Sample splitting in to representative sample
· Weighted sample preparation
· Specimen preparation
Equipment can also include self-cleaning mechanisms for
· Basic internal cleaning
· Specimen tube cleaning
· Sieve cleaning
· Waste redirection to designated outlet
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