Most of the prototype copper rotors produced for the ICA/CDA project were cast using a Buhler 660 metric ton machine, similar to that shown in Figure 11.6.1. Similar to most modern die-casting machines, this Buhler machine can record and document shot profile data for each rotor. An example of a shot curve used to die-cast a copper rotor is shown in Figure 11.6.2. The process parameters used to cast the rotor are listed in Table 11.6.1.
|Slow shot plunger velocity||0.26-0.50 m/sec|
|Fast shot plunger velocity||4.0 m/sec|
|Intensification pressure||920 bar|
|Solidification time||12 seconds|
Although the level of process monitoring described here is not necessary for the production of die-cast copper rotors, it obviously provides valuable information to the die-casting engineer during initial set-up of the process, and to ensure that the process remains in control during commercial production. If older die-casting machines are being used that don't have such process monitoring, retrofit systems can be used from companies such as Visi-Trak. The Visi-Trak True-Trak 2020TM monitoring system features a high-speed data collection system that records injection data from position and velocity sensors. In addition, the Visi-Trak Sure-Trak2TM shot control system can be used to replace the valves and control systems on older machines, to provide real time control of the injection process.
Contact information for Visi-Trak is listed in Table 11.6.2.
|Company Name||Contact Person||Location||Phone Number||E-mail Address||Web Site|
|Visi-Trak||Jack Branden||Valley View, Ohio, USA||+1-216-524-2363||sales@visi-