Die thermal control system

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The temperature distribution of die surface is very important to ensure high quality, high efficiency and nondestructive defects.Shrinkage marks, sand holes, cracks, bubbles and other defects in die casting process are mostly caused by runaway of mold temperature.The infrared thermal imager can monitor the surface temperature of the mold in real time, which can effectively improve the service life of the mold, reduce the energy consumption and production cycle, reduce the maintenance cost by adjusting the mold temperature, reduce mold release agent and lubricant without cutting off the flow.

DTC takes images automatically from the mold before and after spraying for each die casting cycle of mold temperature distribution of total radiation heat maps do save analysis, provide relevant mold heat distribution in the thermal image, and get the detailed information of the mold heat part to help the customer to well understand current technological conditions to make the right judgment. Foundry engineers achieve the fast adjustment of mold temperature through the optimization of die spraying process.

DTC is an independent and "open" device with good opening compatibility with die casting machine unit and peripherals (such as robot, spray head, thermoregulation and die casting machine unit).

DTC is dedicated to serial production quality supervision, to monitor and control of stable production process meanwhile increasing the production output.

The modular software and hardware combination of DTC can be customized according to different usage conditions, 100% to meet the needs of all customers.

DTC hardware is reliable, and software is advanced and practical.

DTC the innovative products equipment can help protect and control appropriate temperature distribution in die casting process by accurate real-time temperature measurement mode without interruption of production or manual operation. Heat temperature phase diagram can help you protect and control appropriate temperature heat distribution in die casting process, heat temperature phase diagram can identify the energy emitted from human body or the target which human eye can't find. This kind advantage can provide the real-time temperature measuring precision without disruptions or manual operation.

As the leader of the infrared technology industry, Inprotec IRT focuses on the thermal camera system and explores the radiation within the scope of the electromagnetic spectrum infrared spectrum, and generates the radiant thermal image. The monitoring of mold temperature plays a crucial role in the different stages of die casting production.

Die temperature distribution effect

Preheating phase: when the die must be gradually heated up to the process requirements.

Serial production: when the mold temperature must be maintained in a stable thermal balance conditions, it is required to achieve the best quality by adjusting thermoregulation and lubrication system and spray flow of release agent.

Better monitoring and management

DTC has an electric control cabinet, a pneumatic system to protect infrared lenses, and a 10-meter compression cable with an industrial connector to connect the camera station. The DTC unit consists of a trolley and two infrared cameras integrated into two air-cooled aluminium housings. Continuous infrared phase images are collected by the camera in real time to achieve real-time process feedback and processing control.

ROIs (Regions of Interest) or POIs (Points of Interest) can be used to monitor special details of die castings, temperature trends, or to compare past and current production batches.

All the information is stored and processed by the computer panel. It is easy to analyze and process the thermal image by downloading the information from DTC via USB.

Benefits of DTC use

Controlled, preset, start-up cycles for extended die life and scrap reduction

Faster sampling of new dies, tools and castings to aid better knowledge of tooling

Optimized spray and lubrication cycle

Spray cycle customized to the release agent in use

Local and punctual measurement of temperature without thermocouples

Live view of temperature distribution of the fix, mobile die

Control and monitoring of the HPDC manufacturing process:

-identity card map of the die

-identity card map of the casting

Series thermographic records for archiving the manufacturing process

Full data collection without distribution of serial production

Indirect benefits of DTC use

Improved surface thermal temperature distribution resulting in lower die thermal shock

Waste water reduction due to optimized spray cycle

Correlation of casting parameters, i.e. casting defect and local die temperature

Enhanced casting quality(cold flows, shrinkages, porosities, die solderings, etc.)

Increased productivity

Improved overall equipment effectiveness of the HPDC cell

Possible management of thermoregulation and cooling system

Potential interface with spray equipment

DTC key hardware features

eliable, robust and easy to transport

IP67 aluminium housings with vortex technology

Simple installation and removal on the die casting machine by the end user

High-tech solution with integrated touch screen panel

Series recording and saving of thermal images on hard disk

Video recording and thermal image storage on hard disk

Data transfer via USB interface

Available in mono and stereo version to monitor fix, mobile or both die halves

Infrared camera resolution 320*256 pixel

Higher infrared camera resolution optional(640*512 pixel)

Autofocus and motorized focus upon request

Remote assistance service by Inprotec

DTC software features

Tailor-made software exclusive to Chem-Trend, available in 6 languages(DE/GB/FR/ES/IT/CN)

Ability to draw up to 10 POIs

Ability to draw up to 10 free ROIs with minimum, average and maximum temperature as reference values

Indication of position of Hot Spot and Cold Spot in the ROI

Ability to set on-screen or external signal threshold limit alarms

Representation of up to one month of temperature trend in video recording with live or archived data download capability

Camera settings such as emissivity, temperature scale and colors palette

Recording of images on event and in manual mode(dedicated button)

Ability to save filecollection to :

-recall the same areas of analysis in the sane position, to manufacture repeated orders

-conduct a post-analysis of the recorded images

Special customer software requirement available upon request(optional)

Visualization of event log and alarm log 

Parameter settings protected by password to prevent unauthorized changes

Conclusion

In the future, it is necessary for real-time monitoring of mold surface temperature, we will continue to improve the intelligent human-machine interaction interface and provide 100% customized services according to user different needs.