Design and Integration of a Multisensory Board for Real-Time Monitoring of Metal Casting Foundry Sand Molds

This paper presents the design and integration of a compact multisensory PCB node designed and aimed at enhancing real-time monitoring of the sand mold curing process in metal casting foundries. The board incorporates the ESP8266 microcontroller, BME680 sensor for temperature, pressure, and humidity readings, and the SGP40 sensor for volatile organic compounds (VOC) level detection independent of humidity. These parameters significantly affect the sand's properties including its moisture content and binder curing process, their tracking thereof would potentially help identify conditions that could lead to dents or breakages in the sand molds and hence proper control of the conditions could ensure that the sand maintains its integrity during the casting process, minimizing defects in the mold. These sensor data create the avenue for proactive adjustments, ultimately improving the quality and reliability of molds during production. The system ultimately aims to mitigate mold dents and breakages by enabling precise environmental monitoring.