Applications
Die casting is a metal casting process that uses a high-precision steel mould to produce complex metal parts. The molten material, generally aluminium, zinc or magnesium, is injected into the mould under high pressure, ensuring strong and detailed components, ideal for sectors such as automotive, electronics and energy, where complex geometric shapes with reduced weight are often required.
Besoins:
Monitoring the closing force
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Measurement of clamping force distribution
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Calibration and testing of tie bar deformation
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Mould position monitoring
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Monitoring the position of the ejectors
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Measurement of pressure in the hydraulic circuit
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Control the electrical heaters of the holding furnace
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Measurement of the temperature of the holding furnace
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Besoin:
Monitoring the closing force
The constant monitoring of the mould closing force in die casting machines guarantees their stability, reducing wear and ensuring high product quality. Timely detection of deviations caused by wear, setting errors or thermal effects makes it possible to prevent rejects, optimise the process and prolong the life of the machine and the mould.
Solution:
The SL76-VDA strain link sensor is ideal for permanent installation on the mould surface, providing an accurate, highly repeatable, real-time measurement of clamping force. With a cyclic reset, it ensures a stable value even in the event of temperature fluctuations caused by the injection of the molten metal and the subsequent cooling phase. The sensor’s robust design makes it suitable for die casting machines subject to strong vibrations, while its mechanical structure means it can be easily installed without changes to the structural design. The SL76-VDA allows operators to monitor machine conditions and process stability, ensuring optimal closing force and reliable, high-quality production.
Besoin:
Measurement of clamping force distribution
The uneven distribution of clamping force on the tie bars of a die casting machine can cause mould misalignment, accelerated wear and defects in the end product. By continuously monitoring the load on each tie bar, it is possible to detect imbalances due to wear, setting errors or deformations. The early detection of such conditions prevents failures, improves process reliability and prolongs the life of the mould and machine.
Solution:
The ML1018 measuring lance is designed for direct installation inside the machine tie bars, where it measures the axial deformation convertible into clamping force. By monitoring all four tie bars, operators can accurately assess the load distribution. Installed near the mould closure area, it provides highly accurate measurements. Because it is in a protected position inside the tie bar, the sensor is not exposed to damage caused by the die casting process. The ML1018 sensor provides continuous feedback on load balancing between tie bars, allowing the identification of unbalances and the prompt correction of the machine settings.
Besoin:
Calibration and testing of tie bar deformation
Regular calibration of clamping force in die casting machines ensures optimal performance, prevents damage and maintains quality. Portable measurements allow operators to quickly detect deviations arising from wear or mechanical/hydraulic variations, ensuring operation within the required parameters and constant quality over time.
Solution:
The QE2008-W wireless strain sensor is the ideal solution for continuous calibration and testing during machine operation. Using pressure technology, it can be rapidly installed on tie bars without adhesives, providing accurate measurements in just a few minutes. Wireless transmission and compatibility with mobile devices simplify the work of service teams, reducing downtime and ensuring constant performance and production quality over time.
Besoin:
Mould position monitoring
Continuous monitoring of the closing force in die casting machines is essential to ensure process stability and consistent quality of the parts produced. Uneven load distribution on the tie bars can cause mould misalignment, accelerated wear and defects. Deviations caused by wear, mechanical drift or hydraulic changes can be quickly detected through regular checks and measurements during calibration or maintenance operations. The early detection of imbalances makes it possible to prevent failures, improve production reliability and prolong the useful life of the mould and machine, ensuring high standards and operational continuity.
Solution:
The WPA series of non-contact linear position sensors guarantees an accurate reading of the mould position in die casting machines. The absence of electrical contact between sensor and cursor eliminates wear problems, ensuring long operation. These sensors offer high precision through linearity, repeatability and low hysteresis. Designed for harsh environments, they are resistant to vibrations, shocks and wide temperature excursions. They are protected from external agents and immune to EMC issues. Available with strokes from 50 to 4000 mm, sliding or floating cursors and different signal outputs, they are versatile and ideal for integration on any die casting machine, guaranteeing reliable measurements and constant quality of the injection process.
Besoin:
Monitoring the position of the ejectors
Accurate monitoring of the position of the ejectors in die casting machines is essential to ensure the precise ejection of items and optimise the entire production cycle. Continuous detection reduces cycle times, prevents ejection errors and improves the overall efficiency of the machine. In particular, the rapid measurement of the ejector stroke allows precise control of the process, reducing defects and unscheduled stops. This approach increases product quality, extends component life and contributes to more stable and reliable production management, with significant benefits in terms of productivity and operating costs.
Solution:
The WPA series of non-contact linear position sensors guarantees an accurate reading of the ejectors in die casting machines. The absence of electrical contact between sensor and cursor eliminates wear problems, ensuring long operation. These sensors offer high precision through linearity, repeatability and low hysteresis. Designed for harsh environments, they are resistant to vibrations, shocks and wide temperature excursions. They are protected from external agents and immune to EMC issues. The availability of short 50 mm strokes, ideal for the measurement of limited ejector strokes, together with sliding or floating cursors and different signal outputs, makes these sensors versatile. Ideal for integration on any die casting machine, they ensure reliable measurements and improve process quality and repeatability.
Besoin:
Measurement of pressure in the hydraulic circuit
Monitoring the pressure of the hydraulic circuit in die casting machines is essential to ensure efficiency, safety and production continuity. These machines operate at very high pressures, with rapid peaks that, if not detected, can damage components and reduce system reliability. The constant measurement of pressure makes it possible to promptly identify anomalies, prevent faults and optimise maintenance. Checking the pressure values in real time also means reducing machine downtime, prolonging the useful life of the plant and improving the quality of the production process, therefore ensuring operational stability and lower operating costs.
Solution:
The pressure sensors of the KS series are ideal for monitoring hydraulic circuits in die casting machines during all processing phases. Operating with stainless steel membrane film technology, they combine robustness and reliability in a compact design.
Key features:
- SIL2 certification;
- Speed of pressure reading (< 1 ms);
- Measurement ranges up to 1000 bar;
- IO-Link communication.
Besoin:
Control the electrical heaters of the holding furnace
In the die casting process, the holding furnace ensures that the molten metal remains at the ideal temperature to guarantee a homogeneous and stable melt during injection. Aluminium alloys, which can reach 700°C, are generally heated by silicon carbide (SiC) electric resistors, powered at low voltage and connected via transformers, ensuring uniform heat distribution. Accurate control of these resistors is crucial to keep the temperature constant, optimise energy efficiency and prevent malfunctions. Continuous monitoring makes it possible to improve the reliability of the furnace and ensure constant quality in the production process.
Solution:
For the precise control of industrial electric heating processes, the Power Controllers of the GPC series, with current rating up to 600A in single, two- and three-phase configuration, represent a compact, robust and extremely high-performance solution, suitable for all types of loads, from linear resistors to transformers. With their configurable functions, integrated diagnostics for predictive maintenance and connectivity with the newest communication protocols, they offer maximum flexibility. The modular I/O allows the complete management of the signals, from the retransmission of the commands to the reading of the process variables. The compact design means these controllers can be installed even in confined spaces, guaranteeing efficiency, operational continuity and reduction of system downtime.
Besoin:
Measurement of the temperature of the holding furnace
Temperature is the most critical variable to be measured to ensure that the molten metal remains at the ideal temperature, ensuring homogeneous, fluid melting and injection repeatability. The probe must be able to work immersed in the molten metal, ensuring stable and continuous measurement. For this purpose, the essential element is the sheath, which protects the sensitive element (usually a thermocouple) and that can be rapidly replaced in the event of failure. The fundamental characteristic of the sheath is the material it is made of, which must be resistant not only to the temperature of the molten metal (up to 700°C) but also to its corrosive action. In such conditions, it is necessary to choose a suitable coating material, which can guarantee reliability and durability.
Solution:
The temperature probes of the TC6 series, equipped with a thermocouple sensitive element, are an ideal solution for heat treatment applications with temperatures that rise up to 1000°C. The possibility of choosing the type of thermocouple, the measuring range, the installation length and the material of the sheath allow for a wide versatility of use, e.g. an INCONEL 600 nickel-chromium-iron base metal alloy sheath is suitable for high temperatures in harsh environments, such as molten aluminium holding furnaces.
Operating principle
The die casting process is a production technique used to manufacture metal components with high precision and excellent surface finish. The main step in the process is the injection of molten metal alloys (such as aluminium, zinc, magnesium) into a preheated metal mould. The molten metal is kept at the ideal temperature by holding furnaces, which ensure its homogeneity and fluidity throughout the injection phase.
The process is divided into two main phases:
- injection of the molten metal into the mould
- cooling that leads to the solidification of the item.
Initially, the metal is melted and maintained at high temperature, before being injected at high pressure (up to 2000 bar) into the mould. The injection speed and high pressure generate strong vibrations that can affect the stability of the machine, which must therefore be designed to withstand these stresses. The pressure is also maintained during the cooling phase, so as to guarantee the correct solidification of the metal and the geometric fidelity of the component.
This process offers numerous advantages for the production of complex components for sectors such as automotive, electronics and energy, because it can be used to obtain high quality parts, with reduced tolerances and high production efficiency. In addition, it minimises waste material, optimising production costs.
Requirements and Technology
To ensure the efficient and precise production of metal components through die casting, it is essential to carefully monitor and control some critical process variables:
- Temperature of the molten metal,
- Injection pressure,
- Mould closing strength and geometry,
- Mould position.
Having the metal at a suitable temperature, which varies depending on the alloy used, is essential to maintain homogeneous and fluid melting, thus ensuring the repeatability of the process during the injection phase.
The control of pressure in the hydraulic circuit is equally important: in die casting systems, pressures may rise to up to 2000 bar, with rapid peaks that, if not detected promptly, can compromise the integrity of the components and cause serious damage.
Finally, supervising the force and the geometry of the mould during the opening and closing phases not only guarantees a high quality product, but also allows the detection of any anomalies in advance, reducing the risk of failures and expensive machine downtime.
