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Casting defects – Surface temperature

Customer – ChemTrend – Inprotec IRT
Casting defects - Surface temperature
Complex and heavy parts – xxx GH

Monitoring and understanding

  • Complete diagnostic

Results

Parameters Old condition Optimization Variation
Average temp before spraying (ºC) 305 307 2
Average temp after spraying (ºC) 98 150 52
Temp variation Pre-Post (ºC) 207 157 -50
Die Lubricant
Process improvements
  • Die surface temperature optimized
  • Die lubricant reduced in 22%
    Wastewater reduction
  • Enhanced casting quality
    The X-ray test showed markedly reduced pores
    Cold flows, shrinkages and die-solderings, were eliminated
  • Increased productivity in +5%
  • Design of the spraying programs on other machines

Customer comments and conclusions

  • Monitoring and controlling the die surface temperature can result on fundamental process improvement
  • The DTC device clearly showed the high benefit as a valuable tool to analyze production processes and to identify any potential optimization
  • The results of the first project showed that the high benefit of the DTC will also pay off the investment in a short time

DTC – Die Thermal Control

Thermography in HPDC

Useful technology to:
  • Understand the thermal balance of a die surface
  • Select the correct Release Agent
  • Adjust its application
Main advantages:
  • Fast (moving objects)
  • Non-contact (no hazard)
  • Overview of temperature
  • Digital data
  • In-line analysis
  • Off-line analysis

The value-added

The DTC is a monitoring device for the series production:
  • Start-up > reduction of scrap rate
  • Die Sampling > reduction of sampling times
  • Improved productivity > shorter lubrication times
  • Criticist «finder» > quality check
The DTC is an «open» device:
  • I/O for interfacing and integration with others devices
  • Analog Input for future applications
    • Interfacing with peripheral possible > Spray-head, Thermoregulator, HPDC machine, etc.
    • Customer tailoring

DTC - Installation on DCM

DTC – Trolley version

    DTC – Fix version

    Developed for OEM to install on HPDC machine
    • All the version of DTC (Trolley, Fix, Remote) have the predisposition for the connection in the Network Ethernet of the customer, and is conforming to the requisite for “Industry 4.0”
    • Each DTC is also however autonomous and accessible in the place where is installed, with access through password.

    DTC – Remote version

    Developed for Custom installation on HPDC machine
    • Panel PC positioned to operator side on mobile arm and electro- pneumatic cabinet installed on wall or on raised support

    DTC – Remote version

    Developed for Custom installation on HPDC machine
    • Panel PC integrated on DCM cabinet and electro- pneumatic cabinet installed on wall or on raised support
    EP Cabinet
    Panel PC
    EP Cabinet
    Panel PC
    Panel PC

    Special Housings

      Infrared cameras

      4 possible choices:
      • FLIR A35
        > 320 x 256 pixel (81.920 temperature points), more lenses available with different FOV (Field Of View)
      • FLIR A315
        > Autofocus/Motorized focus, 320 x 240 pixel (76.800 temperature points), additional lenses available, HT calibration, etc.
      • FLIR A65
        > High Definition version, 640 x 512 pixel (327.680 temperature points), more lenses available with different FOV (Field Of View)
      • FLIR A615
        > Autofocus/Motorized focus, 640 x 480 pixel (307.200 temperature points), more lenses available with different FOV (Field Of View)

      DTC Software – Main page #1

      Movable marker on each image and ΔT between marker 1 and marker 2
      Movable marker on each image and ΔT between marker 1 and marker 2
      Movable marker on each image and ΔT between marker 1 and marker 2
      Temperature difference POST vs PRE lubrication
      Warm-up bar
      Name of Mould
      Date & Time

      DTC Software – Main page #2

      IRT – Analyzer software for PC

      Interfacing

      • Possible interaction with peripheral's
        • Robot
        • Spray head
        • Thermoregulators
        • HPDC machine
      • Active process!
        • Target: closed-ring process
      • Open modular system
      • «Slave»
      • Tailor-made on Customer’s needs

      DIE CASTING INDUSTRY 4.0

      Global approach

      • Many devices affect temperature:
        • TCUs, sprayers, pin coolers, spot coolers, air blowers…
      • In most cases, all these devices are coordinated by process technicians, but there is a lack of integration.
      • Tools must be prepared to control temperature. Tool makers bear the responsibility in making temperature control possible.
      • Temperature control is the result of a synergy of systems.
      Need of a global approach!

      DTC Plugin system - intro

      • Plugins allow full DTC customizations
      • DTC „Plugin“ concept is similar to „app“ for Smartphones device: adapts the device to users specific requirements, without losing the ability to update the system core (new features, optimizazions,..)
      • Plugins are an user interface to……
        • HW systems connected to DTC (thermoregulators, DCMs, Lubrication robots,……)
        • SW systems (MES, Network servers, Network databases,..)
        • DTC's optional devices
        • Customer's special requirements

      Die Casting Industry 4.0

      • The DTC has been tested from IMQ (Institute for the Quality Mark), Institute recognized by Italian Goverment for the asseveration of systems and plants for the Industry 4.0 regulation
      ….the DTC system can be defined "Industry 4.0" because it satisfies all the characteristics indicated at point 12, ….of the circular N.4/E dated 30/03/2017

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