Cycle and Monitor Press: Process Monitoring

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.

Figure 11.6.1: Buhler die-casting machine
Table 11.6.1: Casting parameters used generate the shot curve shown in Figure 11.6.2
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
Figure 11.6.2: Example of a shot curve from a die-cast copper rotor (process parameters used to produce the rotor are listed in Table 11.6.1)

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.

Table 11.6.2: Contact information for Visi-Trak
Company NameContact PersonLocationPhone NumberE-mail AddressWeb Site
Visi-Trak Jack Branden Valley View, Ohio, USA +1-216-524-2363 sales@visi-