01. Brief introduction of die casting industry   At present, the vast majority of die casting machines belong to hydraulic transmission die casting machines, the power of hydraulic transmission system is provided by the motor driven oil pump.  In the process of die casting cycle changes, die casting machine in different processes need different flow and pressure, must rely on flow valve and pressure valve to adjust the different flow and pressure required by different processes.  And when the load change is relatively large, because the output power of the quantitative pump can not be adjusted, so the excess energy can only be consumed in the baffle, oil leakage, oil temperature rise, which also aggravates the wear of various valves, and causes high oil temperature, excessive noise of the motor, and shortened mechanical life and other phenomena.  And usually in the design of the capacity of the motor is much higher than the actual need, there is a "big horse car" phenomenon, resulting in a lot of waste of electric energy.  Therefore, it is of great significance to promote the application of frequency converter in die casting machine to reduce energy waste.       02, die casting machine hydraulic system principle overview     1. Overview of working principle of die casting machine   Hydraulic injection machine is a kind of typical equipment periodic duty, in a complete working cycle (processes) can be roughly divided into clamping, for soup, and shoot, core-pulling, open mode, thimble, cooling, accumulator and so on several stages, each stage is through the oil pump motor pump out of the hydraulic oil into each cylinder drive transmission mechanism through a series of actions,  Each stage requires different pressures and flows.  For hydraulic system, each stage requirements for pressure, flow rate of each different, and the oil pump motor power is based on the maximum load allocation in the process of operation, and the die casting machine of a work cycle, only high pressure clamping and then shoot stage work load is bigger, the other work stage generally small, during the process of cooling load is almost zero.  For oil pump motor, the process of die casting machine is driven by changes in the load state, quantitative pump in hydraulic system, the oil pump motor at a constant speed to provide a constant flow, and the working pressure and flow required size is depends on the pressure proportional valve and flow proportional valve to regulate, by adjusting the pressure or flow proportional valve opening to control pressure or flow rate.  The excess hydraulic oil flows back through the relief valve. This process is called high pressure closure, and the energy loss caused by it is generally around 50%.       2. Overview of energy saving reform principle of die casting machine   According to the working principle ...

The essence of high pressure die casting (die casting for short) is a method that makes liquid or semi-liquid metal fill the cavity of die casting mold (die casting mold) at a high speed under high pressure, and forms and solidifies under pressure to obtain the casting. First, high pressure casting process 1.1 High pressure casting plane layout At present, the general die-casting island will consider the following configuration; Die-casting machine with vacuum, heat preservation furnace is equipped with quantitative casting system, do and product with the type of spraying system, shorten the spraying time, the robot to take parts, slag bag, code cutting and other work, the last cutting to the gate system; The die-casting island can also be upgraded for automated cleaning under high volume conditions. 1.2 APPLICATION of CAE simulation software CAE analysis is more and more widely used in die casting industry, represented by PROCAST, MAGMA, flow-3D, etc. According to the calculation results of filling flow and velocity distribution, the simulation can accurately predict the defects such as enrolling, inclusion and bad filling, which greatly improves the yield and saves a very objective cost. It is a very useful tool to quickly and scientifically design the whole casting system (gate, sprue and overflow tank, etc.) for die casting. Optimize casting process parameters, reduce the number of mold testing, reduce casting cost, improve product quality. CAE software was used for general analysis of filling, solidification, porosity distribution and velocity distribution reports (as shown in Figure 2). 1.3 Application of vacuum die casting With the continuous supply of product quality requirements, the use of vacuum to solve the problem of filling and air tightness of castings has been well developed, and vacuum valve is generally used, the most commonly used vacuum valve has the following two structures. Figure 3 is the schematic diagram of the vacuum valve. Like ordinary die casting process, after aluminum water enters the chamber, vacuumization begins to start. Then, when the die casting machine starts at high speed, the kinetic energy of aluminum water is relied on to touch the spring plate of the vacuum valve. When using a mechanical vacuum valve, it is generally closed when preheating the mold. When the preheating is complete, the vacuum valve can be used only when the high speed and pressurization is started. Mechanical vacuum valve has the advantages of simple use, but the processing accuracy of vacuum valve is high, and the cost of vacuum valve is relatively high. Figure 4 is the schematic diagram of the hydraulic vacuum valve. The principle of the mechanical vacuum valve is the same. When the punch starts, the vacuum starts, but the principle of closing the vacuum valve is different. When the hydraulic vacuum valve is generally started at high speed, the type is sent to the hydraulic system o...

Ways to improve the service life of die casting The durability of the mold depends on: 1) Choose high-quality die steel. 2) Good mold design and manufacturing process. 3) Optimized processing technology. 4) Operation specification, maintenance and maintenance in the process of use. ----------------------------------------------------------------------------------------------------- 1. Mold material selection Material selection determines many important properties of the die, such as plasticity, toughness, thermal conductivity, hardenability, creep strength, high temperature yield strength, resistance to backfire, thermal expansion coefficient and so on. 1) The plasticity, strength and creep strength of materials at high temperature are the main factors to determine the degree of crack generation. The toughness of the material determines the degree of crack propagation. 2) High thermal conductivity can reduce mold temperature difference and reduce thermal stress. 3) Low thermal expansion coefficient means small expansion volume and thermal stress accumulation. 4) High temperature yield strength is beneficial to resist mold cracking. 5) Resistance to backfire is to make the mold has a long time of high temperature resistance to softening performance. 6) Choose high-quality die steel, high purity and uniformity of steel, less impurities is the key to durability. ----------------------------------------------------------------------------------------------------- 2. Good die design 1) The mold structure should meet the requirements of die casting technology, machinability, heat treatment and use. 2) The rationality of the structure: the rationality of the structure is the rational design of the pouring system. After the structural form and layout of the pouring system are determined, it provides the basic basis for the overall design of the mold. 3) Mold wall thickness: the strength and stiffness requirements of the mold should be fully taken into account. When the mold wall thickness is insufficient, the cavity is easy to deform under high pressure. After deformation, the sharp corner or fillet radius which is easy to cause stress concentration will crack. 4) Cooling channel: the reasonable design of the position, spacing and size of the cooling channel can ensure that the mold works within a reasonable and constant temperature range, and avoid the thermal deformation of each part of the mold due to the large temperature difference.

Die casting machine operation specification 1. Pre shift preparation 1.1 die casting workers must wear labor protection articles as required at work, including work clothes, work shoes and work hats. It is strictly prohibited to wear vests, shorts and shirtless. 1.2 the die casting worker must arrive at the post 20 minutes in advance for pre job preparation, including: View shift change records Prepare class II tools and inspection tools required for production Check the product quality of the last shift, this shift and other shifts 1.3 15 minutes before shift handover, the team leader shall gather the team members to hold a pre shift meeting, including: The shift leader shall arrange and adjust the work on duty The monitor shall convey the company's decision The monitor introduces various problems existing in the work time, reminds employees and puts forward requirements. 2. Production preparation verification 2.1 before production, it must be verified according to production preparation verification, including process verification: Check whether the actual process on site is consistent with the process card Input and check the process without input item by item 3. Machine start 3.1 before starting the machine tool, the aluminum die casting machine tool must be comprehensively checked to ensure that the die-casting machine tool is in normal state. 3.2 before starting the machine tool, manually lubricate it for 3 times before starting it. 3.3 jog to start the machine tool and observe the operation of the machine tool. If there is any abnormality, stop the machine immediately. 3.4 after the machine tool is started, the cooling water shall be turned on to prevent the oil temperature from rising. 3.5 in case of machine tool failure or alarm signal, immediately check the cause and report for repair. It is strictly prohibited to work with machine tool failure. 4. Mold installation for pressure casting machine

Problems easily ignored in horizontal type cold chamber die casting machine production site 1: The correct connection, coordination and maintenance are as shown in (Figure: 1): (1) the injection plug rod, injection rod assembly and molten cup hole shall be coaxial and the axis shall be repeated. The connection shall be firm without obvious looseness. There shall be no obvious gap at the cladding. (2) : the cushion block shall be replaced frequently (prepared according to the actual size between the injection rod and the piston rod). (3) : the connection between the ejector rod, transition joint and ejector head shall be kept tight. (4) : keep the cooling water unblocked. (5) : the injection head shall be well lubricated. Special precautions: (1) : do not use a bent ejector rod. (2) : do not use the injection head with different inner hole thread and outer circle core, and the melting cup with different inner and outer circle core. 2: Incorrect connection and fit are shown in (Figure: 3) Cause of the problem: due to thousands of injection shocks every day, the length of the cushion block between the injection rod and the piston rod is gradually shortened, resulting in the gap between the injection rod, the piston rod and the inclusion part of the split wrap clamp. When the gap is large to a certain amount, the results shown in (Figure: 3) will appear. This is a problem that many factories have neglected for a long time. It causes permanent deformation of the end face of the injection piston rod (the end face is not perpendicular to the axis) or even fracture. Make the injection head, injection rod assembly and molten cup operate under the condition that different axes and axes do not repeat. Main features of fault: (1). The ejector rod is often bent and deformed. (2). Excessive joints often break. (3). Always jam the ejector head. The service life of the ejector head is short. (4). The single side wear of the injection head, the melting cup and the gate sleeve on the die is very fast. Aluminum liquid often splashes outward from the gap between the molten cup and the injection head. Or the flash on one side of the material handle is very large. (5). The repeated precision of equipment injection action is poor, so that the product quality is unstable. Once this problem is formed, the ejector head will often be replaced in the production process, and the general technicians will give the wrong conclusion of "poor quality of ejector head and no wear resistance". 3: The simple judgment method of brass alloy die casting machine is shown in (Figure: 4) (1) Simple measurement: carry out physical die casting machine with manual program. After the die casting action is completed, measure whether there is obvious difference between the surrounding gap between the injection rod and the molten cup. If there is a large difference, it indicates that the injection rod or piston rod has been deformed (generally, it is normal if the center deviation is within 0.2mm...

Introduction: before industrial robots brought vitality to the automobile industry, the application scope of industrial robot technology in the manufacturing industry in the world has become wider and wider. It has been extended from traditional manufacturing industry to other manufacturing industries, and then to various non manufacturing industries, but the automobile industry is still the main application field of industrial robots. It is understood that% of industrial robots in the United States are used in automobile production; Used in the automotive industry worldwide. Before industrial robots brought vitality to the automotive industry, the application scope of industrial robot technology in the manufacturing industry has become wider and wider in the world. It has been extended from traditional manufacturing industry to other manufacturing industries, and then to various non manufacturing industries. However, the automotive industry is still the main application field of industrial robots. It is understood that% of industrial robots in the United States are used in automobile production; Industrial robots used in the automotive industry in the world have reached 37% of the total consumption, and industrial robots used in automotive parts account for about 24%. In China, the initial application of industrial robot is in automobile and construction machinery industry, mainly used for spraying and welding of automobile and construction machinery. At present, due to the backwardness of robot technology and R & D, industrial robots are mainly used in manufacturing and less in non manufacturing. According to statistics, in recent years, more than half of the industrial robots produced by domestic manufacturers are provided to the automotive industry. It can be seen that the development of automobile industry is one of the driving forces for the growth of industrial robots in China in recent years. At the same time, in the "notice on organizing and implementing the development of intelligent manufacturing equipment" issued by the national development and Reform Commission, the Ministry of finance, the Ministry of industry and information technology and other ministries and commissions, according to the current situation of the development of intelligent manufacturing equipment in China, the "special" will focus on supporting the research and development of intelligent complete sets of equipment and key intelligent components required in automobile manufacturing and other fields, In the near future, it will focus on promoting the application of industrial robots and key intelligent components, such as robot automobile welding automation production line related to automobile, digital workshop and intelligent logistics system. Among the new national major technical equipment projects with demand as the traction, process as the guide, emphasis on user participation and finally aiming at the industrialization and transformation results, there ar...

Introduction: save the release agent: the amount of robot spray and artificial spray release agent is the same. It saves more than half of the dosage of the release agent, and the spray position is more accurate than that of the traditional sprayer. It can improve the quality of the product. The copper tube sprays, because of the air pressure reason, the copper tube will be changed after a few hours, and it needs to be adjusted manually, while the robot fixed the spray. High accuracy and many stored programs: can the robot be right.  Save release agent: The dosage of the robot spray and the artificial spray release agent is the same, which saves more than half of the releasing agent dosage than the traditional sprayer The spray position is accurate: it can improve the quality of products. The copper tube sprays, because of the air pressure reason, the copper tube will be changed after a few hours, and it needs to be adjusted manually. Storage program: robot can store more than 99 spray programs for different molds, write programs, and then tune them out for use. Life expectancy: after 4 years of conventional sprayers, there are many problems, such as slideway and guideway wear, and the robot will live longer than 8 years under proper operation. Robot flexibility is high: the traditional sprayer can only spray, and when the robot changes the fixture, it can also be used for picking or other purposes. Program changes are simple: The robot has a hand-held programmer for easy operation.  The fault rate is low: the traditional sprayer will be repaired several times on average, but the robot will hardly fail at the correct operation.

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