Design Of Clamp Sensor Calibration Visualization Tool On The FICO AMS-i Machine

Abstract

Abstract—The Fico AMS-i molding machine relies on the Unwanted Object Detection (UOD) system, whose clamp sensors require precise calibration. Traditional manual calibration using a multimeter poses safety risks from short circuits and is operationally inefficient, requiring two technicians and up to 20 minutes. This study proposes the design and implementation of a 3D-printed digital voltage visualization tool directly integrated into the machine to provide real-time sensor feedback. Accuracy validation against an industry-standard Fluke multimeter yielded an error rate of < 1%, surpassing the SNI IEC 60051-1:2009 Class 3 standard. Furthermore, a 30-day Statistical Process Control (SPC) analysis verified the presence of sensor drift, highlighting the tool's necessity. The implementation successfully eliminated probing hazards and reduced calibration time to 5 minutes by enabling a single-operator workflow, thereby supporting Condition-Based Maintenance (CBM) and Overall Equipment Effectiveness (OEE).