DIE SURFACE TEMPERATURE MONITORING

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1 DIE SURFACE TEMPERATURE MONITORING

2 Optimize your die casting process The surface distribution of die temperature is crucial for high quality, efficient and faultless processes. The most of defects in die casting, such as shrinkage, porosity, cracks, blisters are caused by die temperature out of control. Real time measuring of die surface temperature, without any interruption of production cycle, prevents or nips casting problems in the bud. High or too low die temperature have negative impact on part quality, on tool life, on cycle time, as well as on energy consumption and maintenance costs, due to unnecessary use of thermoregulation, compressed air, water based lubricant, release agents. Die casting process optimization. Thermal images of die temperature distribution automatically taken at every cycle, before and after spraying phase, provide information about thermal behaviour of the mould and lead users to immediate conclusions about process conditions. Casters has then the chance to take fast modifications of die temperature settings through spraying phase optimization. TTV Total Thermal Vision is an innovative and proven technology to real time monitor the thermal map of the die in high pressure die casting process of light alloys. Years of experience and several units operating worldwide, make TTV the most sought-after system to increase die casting quality and overall equipment efficiency (OEE). TTV is the key to efficient part quality control and process optimization. With TTV, users are now able to reach the highest quality level in casting processes to meet the most rigorous demand, obtaining at the same time an optimum die process monitoring solution along with the best practice in die lubrication. 2 TTV

3 watching right die surface thermal map Blisters Shrinkage Porosity Cracks, cast surface roughness, grey or yellow spots, incomplete cast, part bending, rust are recognized casting defects correlated to die surface temperature, spraying operations or lubricant specifications / effects. Mold temperature's influence on die casting Internal defects Macro/interdendritic shrinkage layer porosity Porosity due to air, lubricant entrapment, hydrogen Joint, lamination, cold shot Cracks, hot tear Sink Surface defects Joint vortex, lamination, cold shot Surface deposit, contamination, inclusion Cracks, hot tear Soldering, thermal fatigue, ejection mark Die surface temperature before spraying Die surface temperature after spraying Geometrical defects Incomplete casting Flash Deformed parts TTV 3

4 The IR cutting-edge technology Total Thermal Vision, without any stop of production cycle nor altering the thermal balance, provides a huge amount of reliable data to keep casting process under control, shorter operating time, higher quality at lower cost. The core of the equipment are high quality and performance IR sensors, optics and image elaboration devices, wholly contained in a cylindrical stainless steel housing. A Germanium glass (transparent to IR) protected by an air operated shutter and a cleaning air flow, allows TTV infrared cameras to operate in the aggressive foundry environment. TTV IR Cameras are installed in the optimal position to frame both the fixed and the movable parts of the die, when they are completely open to allow the ejection of the part. IR Optic TTV camera versions TTV Thermal Imaging Camera Microbolometer Video processing electronics To control unit To guarantee constant accuracy and performances of inner IR sensors, the TTV infrared cameras are equipped with an air cooling system automatically controlled, and insensitive to the ambient temperature changes. Focus Fixed Auto Temperature range Accuracy Dimensions Weight C ( F) ±5 C or ±5% of read mm (16,1 7.5") ~5.5 kg (~12.1 lb) C ( F) ±2 C or ±2% of read mm ( ") ~9.5 kg (~20.9 lb) Protection IP65 IP65 To PLC 4 TTV

5 for high quality in die casting All available TTV IR Cameras perfect fit on HPDC machines assuring best region of interest resolution, appropriate global image dimensions, right focus at a fixed camera position. Imaging & Optical Data Distance [m] a b α = 45 Image size [mm] b c Resolution [mm] c α Image size [mm] α = 25 b c Resolution [mm] a min a max TTV Human interface presents to the operator on a wide touch screen the real time die thermal map with immediate warning in case of higher or lower temperature of one or more RoI. Shot after shot, automatic updating of a sample plot of die temperature allow the operator to check die temperature evolution during a defined period of process. Moreover, die thermal map images before and after spraying phase, along with data of RoI temperature are stored into the unit to evaluate and analyze past cast cycles. These features, all in a single station, are the essential stones to build a digital smart 4.0 casting factory. TTV 5

6 Competence experience technology How many aluminium tons foundries are wasting during warm up phase? Customers using Total Thermal Vision to set the ideal thermal ramp to safeguard the die life, report near 70% reduction of rejected parts during warm up phase and faster cycle time of warm up shots. A reduction which represents, in one year, a remarkable saving of thousands of scrap parts and related shots to improve press efficiency. Die surface real time temperature monitoring and traced evolution of defined RoI allow the early identification of major casting defects. Soldering, contamination, shrinkage, ejection marks, lamination are some defects caused by incorrect die surface temperature. Monitoring the delta of die temperature before and after spraying, TTV users can reduce of seconds the time of die lubrication and air blowing, which is the only phase of HPDC process that can be shortened and optimized. The thermographic map of the die surface makes possible optimal lubrication phase and a deep knowledge of the process assuring several benefits to users, leading to an increase of OEE. SAVING Spraying blowing Ejection 38% 8% 10% Die opening 14% Solidification 8% Injection 12% Die closing 10% Pouring Scraps due to production starts and restarts Build/up on the die and patches on the casting Soldering and ejection marks Surface finishing and compaction Filling defects Others Benefits Cost savings Increased die lifespan Optimized cycle time Increased machine efficiency Better analysis of process failures Minor uncontrolled process stops Process identification and part history Efficiency TTV Benefits 6 TTV

7 innovation partnership - worldwide presence Marposs, worldwide leader in high precision equipment for measurement and control in production lines for mechanical industry, acquired from Motultech-Baraldi, a company specialized in research and production of the full range of lubricants and systems for their correct application in high pressure die casting, the TTV ltd, inventor of this innovative technology for real time monitoring of the thermal map of a die surface. Innovation and high technology, principles characterizing Marposs Group products, will give a new impulse to the development and diffusion of IR vision technology, assuring highest efficiency in die casting process of the future. Two specialists offer now adequate solutions to the worldwide most challenging targets, combining the exact measurement of the surface temperature with the best application of release agents, assuring everywhere a complete pre- and after sales service. Being present in 21 countries with 80 offices, MARPOSS provides worldwide close, immediate and qualified assistance to the Customers, speaking their language. Marposs headquarter - Bologna (Italy) TTV 7

8 For a full list of address locations, please consult the Marposs official website D6C09900G0 - Edition 11/ Specifications are subject to modifications Copyright 2017 MARPOSS S.p.A. (Italy) - All rights reserved. MARPOSS, and Marposs product names/signs mentioned or shown herein are registered trademarks or trademarks of Marposs in the United States and other countries. The rights, if any, of third parties on trademarks or registered trademarks mentioned in this publication are acknowledged to the respective owners. Marposs has an integrated system for Company quality, environmental and safety management, with ISO 9001, ISO and OHSAS certification. Marposs has further been qualified EAQF 94 and has obtained the Q1-Award. Some models of the product line, or parts of them, may be subject to export restrictions if exported outside the European Union or may be subject to restrictive measures adopted by the competent national, supranational or international authorities.