Integrated Cell. Peripheral equipment for Evolution & Carat.

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1 Integrated Cell. Peripheral equipment for Evolution & Carat.

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3 The integrated future for die casting cells with Bühler peripheral equipment. High productivity requires casting cells provided with die casting machines that are carefully matched to the peripheral equipment. Centralized cell set-up and operation reduce the time requirements and increase the system uptime. The heart of any casting cell is the die casting machine. An integrated cell with the control system of the die casting machine acting as master facilitates production changes and increases system utilization during production. In particular, it simplifies the saving of die programs and component-specific data. Convenient and centralized control during production starts allows complete loading of all die programs and set-up data from the machine control system. Bühler offers you the following integrated peripheral equipment: BuhlLadle A ladling unit in three sizes with very high ladling accuracy for shot weights ranging from 0.5 to 60 kg. BuhlSpray linear Two-axis unit in different sizes covering the entire locking force range of the Carat series, with up to 8 die spray and blowing circuits. BuhlRob Partially integrated with bus link, based on the proven ABB Foundry plus robot systems. BuhlMark An integrated component marking unit for retracing cast components and their production data. SmartVac An integrated vacuum system for Carat die casting machines. A large number of additional peripheral units from a wide selection of manufacturers can be applied with the die casting machine through digital interfaces. INTEGRATED CELL Peripheral equipment for Evolution & Carat 3

4 BuhlLadle. Ladling units. The fully integrated ladling unit in three sizes The rugged construction based on a simple design contributes to high uptimes of the casting cell. Height adjustability and simultaneous movement of both axes allow metal ladling into the port of the shot sleeve with pinpoint accuracy. The large horizontal traveling distance allows a high degree of freedom in placing the unit and additionally offers appreciably better access to the filling port compared with gantry solutions. High customer benefit is generated by the integration of the control system in the control unit of the die casting machine: Setup is based on the same operating philosophy, eliminating additional training costs. The comprehensive diagnostic solutions of the control system are also available for the ladle. The application of absolute encoders eliminates the need for referencing during starts, making the installation ready for operation within a shorter time and therefore reducing costs. The servo-technology applied on the one hand allows free programming of speeds and ladle angle, and the excellent position accuracy on the other hand allows very high constant ladling rates, helping minimize the cycle times of the unit. The servo-technology selected for all Bühler peripheral equipment is designed to reduce spare parts inventory costs. At least double the service life of RFM ceramic ladles translates into lower operating costs. No coating of the ladle is needed, with appreciably lower temperature losses during ladling, both favoring the cast component quality. BuhlLadle Features Liquid aluminum ladling at very constant rates Ladling into the shot sleeve with pinpoint accuracy Cast steel and durable ceramic ladles available Synchronized with the die casting machine 4 INTEGRATED CELL Peripheral equipment for Evolution & Carat

5 Technical data BuhlLadle Modell 1_12 Modell 2_23 Modell 3_60 Ladling volume / cycle kg (Al) 2 23 kg (Al) kg (Al) Horizontal travel 1825 mm 2250 mm 3100 mm Bath level descent 770 mm 820 mm 1200 mm Connected power 3.7 kw 5.0 kw 15.5 kw Dimensions of ladling unit (LWH) mm mm mm Weight of ladling unit 650 kg 800 kg 2650 kg Dimensions of control cabinet (LWH) Datanet / Dataview Datanet / Dataview Datanet / Dataview Height adjustment of casting cell 350 mm 420 mm 600 mm Ladling accuracy +/ 1.5 % +/ 2 % +/ 2 % Suitability for Evolution L 90 90L BuhlLadle 1_12 * 2_23 * 3_60 * Suitability for Carat L L L L L L L L L L L BuhlLadle 1_12 * 2_23 * 3_60 * Furnace dimensions Required dimensions of the ladle in mm BuhlLadle 1_12 BuhlLadle 1_12 BuhlLadle 2_23 BuhlLadle 2_23 up to 5 kg up to 12 kg up to 12 kg up to 23 kg Rectangular ladle, minimum length Minimum width Round ladle, minimum diameter Minimum bath depth Maximum furnace wall thickness Furnace height The furnace height must be adjusted to the type of installation of the die casting machine, the injection position, and the ladling unit. Suitable Suitable under certain conditions * valid for injection unit Compact Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 5

6 BuhlSpray. Linear die spray unit. The fully integrated two-axis die spray unit in three versions Its rugged construction based on a simple design contributes to achieving a high uptime of the casting cell. Available with tools with up to 8 spray and blow circuits, the unit is highly suited also to very demanding die cavities. High customer benefit is generated by the integration of the control system in the control unit of the die casting machine: Setup is based on the same operating philosophy, eliminating additional training costs. A hand unit with display screen is available for programming. It is applied as a second mobile screen of the control system. It allows the caster to carry out programming and to obtain information anywhere in the cell. Proportional control technology allows programming of spray and air pressures in the time sequence of the core spray program. The core spray programs can be loaded onto the control system together with the die program. The diagnostic options of the machine control system are available also for the die spray unit. The absolute encoders eliminate the need for referencing during starts, making the installation ready for operation within a shorter time and therefore at lower cost. Both axes can be moved simultaneously, allowing linear diagonal motions. The Flextool or Deltacast spray tool from Acheson is a highly proven technical solution and thanks to its clear design very resistant to trouble, resulting in increased uptimes. Depending on the field of application, different mixing and tank units can be selected. Also Wollin devices available as integrated sprayer. 6 INTEGRATED CELL Peripheral equipment for Evolution & Carat

7 Features of BuhlSpray linear Application of two liquid die release agents at controlled rates Atomization of the release agent by air using four, six or eight spray and blow circuits Cleaning of the die surface using two high-pressure blow circuits Cycle time minimizing by high dynamics Tracing of the die contour, also diagonally Acheson Flextool and Deltacast* die spray tools can be attached Wide selection of mixing and tank units * optional Technical data BuhlSpray Model 1M 4/2 V1000 H800 V1000 H1000 V1200 H1000 V1400 H1200 V1600 H1400 Vertical stroke 1000 mm 1000 mm 1200 mm 1400 mm 1600 mm Horizontal stroke 800 mm 1000 mm 1000 mm 1200 mm 1400 mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Drive type AC-Servo AC-Servo AC-Servo AC-Servo AC-Servo Connected power 8 kw 8 kw 8 kw 8 kw 8 kw Dimensions of sprayer (LWH) mm mm mm mm mm Weight of die spray unit 650 kg 650 kg 650 kg 700 kg 700 kg * optional Application of BuhlSpray 1M 4/2 linear Model L 90 90L L 1M 4/2 V1000 H800 1M 4/2 V1000 H1000 1M 4/2 V1200 H1000 1M 4/2 V1400 H1200 1M 4/2 V1600 H1400 Suitable Suitable under certain conditions Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 7

8 BuhlSpray. Linear die spray unit. Technical data BuhlSpray Model 2M 6/2 V1200 H1200 V1400 H1200 V1600 H1200 V1600 H1600 Vertical stroke 1200 mm 1400 mm 1600 mm 1600 mm Horizontal stroke 1200 mm 1200 mm 1200 mm 1600 mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power 11 kw 11 kw 11 kw 11 kw Dimensions of sprayer (LWH) mm mm mm mm Weight of die spray unit 1050 kg 1050 kg 1050 kg 1100 kg Model 2M 6/2 V1800 H1800 V2000 H1600 V2000 H1800 V2000 H2000 Vertical stroke 1800 mm 2000 mm 2000 mm 2000 mm Horizontal stroke 1800 mm 1600 mm 1800 mm 2000 mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power 11 kw 11 kw 11 kw 11 kw Dimensions of sprayer (LWH) mm mm mm mm Weight of die spray unit 1100 kg 1150 kg 1150 kg 1150 kg * optional Application of BuhlSpray 2M 6/2 linear Model L 90 90L L L L L L L L 2M 6/2 V1200 H1200 2M 6/2 V1400 H1200 2M 6/2 V1600 H1200 2M 6/2 V1600 H1600 2M 6/2 V1800 H1800 2M 6/2 V2000 H1600 2M 6/2 V2000 H1800 2M 6/2 V2000 H2000 Suitable Suitable under certain conditions 8 INTEGRATED CELL Peripheral equipment for Evolution & Carat

9 Model 3M 8/4 V1800 H1600 V2000 H1600 V2000 H2000 V2500 H2000 Vertical stroke 1800 mm 2000 mm 2000 mm 2500 mm Horizontal stroke 1600 mm 1600 mm 2000 mm 2000 mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power 22 kw 22 kw 22 kw 22 kw Dimensions of sprayer (LWH) mm mm mm mm Weight of die spray unit 1700 kg 1750 kg 1800 kg 1800 kg Model 3M 8/4 V2500 H2500 VT2000 H1600 VT2500 H2000 VT2500 H2500 Vertical stroke 2500 mm 2000 mm 2500 mm 2500 mm Horizontal stroke 2500 mm 1600 mm 2000 mm 2500 mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Flextool/Deltacast* Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power 22 kw 22 kw 22 kw 22 kw Dimensions of sprayer (LWH) mm mm mm mm Weight of die spray unit 1850 kg 1750 kg 1800 kg 1850 kg * optional Application of BuhlSpray 3M 8/4 linear Model L L L L L L L L L L L M 8/4 V1800 H1600 3M 8/4 V2000 H1600 3M 8/4 V2000 H2000 3M 8/4 V2500 H2000 3M 8/4 V2500 H2500 3M 8/4 VT2000 H1600 3M 8/4 VT2500 H2000 3M 8/4 VT2500 H2500 Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 9

10 BuhlRob. Robot. Robots for Bühler die casting cells. The rugged construction of the proven ABB robots constitute the basic equipment of the BuhlRob systems. All units of Foundry Plus Version ensure trouble-free service of the cell in demanding everyday foundry operations. Customer benefit through partial integration with the cell control system: Setup is based on the same operating philosophy, eliminating additional training costs. All messages and alarms required for operating the casting cell are available at the HMI of the control system. The robot is controlled during operation from the operator terminal of the die casting machine. The diagnostic options of the control system are available for the robot system. Compensation movements by monitoring of the biscuit thickness prevent collisions during component extraction and therefore interruptions of operation. The following are standard programs: Extraction by biscuit gripper and checking for completeness. Component cooling in the cooling bath and depositing in the press and/or discharge to the chute. Functions or interfaces such as insertion, preheating, washing, etc. are additionally available. Completely assembled equipment and complete programming are standard. This reduces start-up times. The robot is supplied directly by ABB. The additional Bühler equipment is attached on site. The cast components are extracted using a rugged biscuit gripper. It can be applied for different diameters. Special contour gripper solutions are possible. 10 INTEGRATED CELL Peripheral equipment for Evolution & Carat

11 Technical data BuhlRob BuhlRob Model 2600F / Technical data Number of axes 6 Handling weight (gripper and load) Maximum reach Programming Connected power Interference contour robot (no gripper and load) (radius) Robot weight Dimensions of control cabinet (LWH) 20 kg 1653 mm RAPID 4.5 kva 348 mm 272 kg (1370) mm Application of BuhlRob 2600F / Evolution *300 *300 *300 *600 BuhlRob Model 4600F / Technical data Number of axes 6 Handling weight (gripper and load) Maximum reach Programming Connected power Interference contour robot (no gripper and load) (radius) Robot weight Dimensions of control cabinet (LWH) 45 kg 2050 mm RAPID 7.8 kva 400 mm 425 kg (1370) mm Application of BuhlRob 4600F / Evolution *100 *100 *300 *500 *600 *600 Suitable Suitable under certain conditions * Base height in mm Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 11

12 BuhlRob. Robot. Technical data BuhlRob BuhlRob Model 4600F / Technical data Number of axes 6 Handling weight (gripper and load) Maximum reach Programming Connected power Interference contour robot (no gripper and load) (radius) Robot weight Dimensions of control cabinet (LWH) 40 kg 2550 mm RAPID 7,8 kva 400 mm 440 kg (1370) mm Application of BuhlRob 4600F / L Carat *500 * L 90 90L Evolution *300 *300 *400 *400 *400 *400 BuhlRob Model 6700F / Technical data Number of axes 6 Handling weight (gripper and load) Maximum reach Programming Connected power Interference contour robot (no gripper and load) (radius) Robot weight Dimensions of control cabinet (LWH) 205 kg 2794 mm RAPID 13 kva 650 mm 1260 kg (1370) mm Application of BuhlRob 6700F / L L L L L L L L L L L *300 *300 *400 *400 *400 *400 *500 *500 *500 *500 *700 *700 *700 *700 *800 *800 *800 *1000 *1000 *1000 *1000 *1000 *1000 *1000 Carat 84 84L 90 90L Evolution *0 *0 *0 *0 Suitable Suitable under certain conditions Track motion required * Base height in mm 12 INTEGRATED CELL Peripheral equipment for Evolution & Carat

13 BuhlRob Model 6700F / Technical data Number of axes 6 Handling weight (gripper and load) Maximum reach Programming Connected power Interference contour robot (no gripper and load) (radius) Robot weight Dimensions of control cabinet (LWH) 150 kg 3200 mm RAPID 13 kva 650 mm 1270 kg (1370) mm Application of BuhlRob 6700F / L L L L L L L L L Carat *400 *400 *500 *500 *500 *500 *700 *700 *700 *700 *800 *800 *800 *800 *1000 *1000 *1000 *1000 *1000 *1000 BuhlRob Model 7600F / Technical data Number of axes 6 Handling weight (gripper and load) Maximum reach Programming Connected power Interference contour robot (no gripper and load) (radius) Robot weight Dimensions of control cabinet (LWH) 150 kg 3500 mm RAPID 13 kva 700 mm 2500 kg (1370) mm Application of BuhlRob 7600F / L L L L Carat *600 *600 *600 *600 *800 *800 *800 *800 *1000 *1000 Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 13

14 BuhlMark. Marking device. BuhlMark is a flexible marking device used for fast and permanent parts labelling and ensures the absolute traceability of cast parts. The device is built to be used in tough foundry environments and has a completely protected stamping unit. Highest degree of flexibility BuhlMark is extremely well-suited to meet the individual demands of parts marking. It only requires very short amounts of time for stamping and works well in applying alphanumeric symbols and codes. Three different types of stamping stylus stamping, dot-matrix stamping and Datamatrix coding allow for flexible labelling. User-friendly BuhlMark is integrated in the Bühler casting cell control system and follows the operating philosophy of the die casting machine. This makes it easy to use during production and refitting and also saves in costs for additional training. Efficiency and low maintenance The marking device requires hardly any maintenance and provides savings in the use of air and electricity. 14 INTEGRATED CELL Peripheral equipment for Evolution & Carat

15 Scribing Highly suitable for use on almost any plastically formable materials Very low-noise marking process with visually attractive text appearance Also suited to slightly curved surfaces Low force applied to the work Dot embossing Highly suitable for use on almost any plastically formable materials Discrete dots, often in conjunction with data matrix coding Especially suited for deep marking Low force applied to the work Data matrix Camera-readable 2D code (ECC 200) same tool as for dotted text. Process-reliable code that may still be readable even after hardening, abrasive blasting, or application of thin coatings. Can be applied on almost any plastically formable materials INTEGRATED CELL Peripheral equipment for Evolution & Carat 15

16 BuhlMark. Marking device. Marking times for scribing and dot embossing (approximate)* Font set A: DIN 1451 or OCR-A scribing Font set B: HS (fast writing = slightly angular characters) scribing Font set C: 7 5 (dot matrix) dot embossing only The following marking cycle times were achieved with a marking unit 315 with marking controller EG-Box (ZAM5) with the marking heads DD20 L and R32 K. Font height SH 1.8 mm SH 2 mm SH 2.5 mm SH 3 mm SH 4 mm SH 5 mm SH 6 mm SH 7 mm Figure set A B C A B C A B C A B C A B C A B C A B C A B C 2 figures figures figures figures single-spaced figures single-spaced figures single-spaced Max. figures / second Marking time for data matrix code ECC 200 (approximate)** Embossing: bidirectional = forward and backward embossing Code size in mm 6 6 mm 9 9 mm mm mm mm mm Embossing mode Bi Bi Bi Bi Bi Bi dots dots dots dots dots dots dots * All descriptions are purely marking times in-feed movements of the marking unit or marking head as well as intermediate movements and movements towards the marking position or return to Home Position are not included. The marking times are reference values. Binding time specifications are only made by marking trial with an original workpiece. The marking speed can have a significant impact on the marking. The quality of the marking depends also on the built-in situation, rigidity of the marking unit parts (please notice our installation instructions), marking position, workpiece geometry and surface of the workpiece. ** All times stated are pure marking times, exclusive of feed travel of the marking unit or marking head or of detour travel and lengthy travel to the marking point. 16 INTEGRATED CELL Peripheral equipment for Evolution & Carat

17 A complete component marking system Profibus BuhlRob Partially integrated in Datanet BuhlMark Partially integrated in Datanet Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 17

18 SmartVac. Vacuum System. Fully Integrated and Flexible in its Application Fully integrated in the die casting machine, the SmartVac system makes it possible to control and monitor commercial vacuum valves. This includes self-closing valves that are mechanically, thermally and hydraulically activated or combinations of vacuum valves that are hydraulically and thermally activated. This allows for up to four extraction points on the die and one extraction point on the shot sleeve to be simultaneously and independently activated and monitored directly from the machine control system. In addition, having an automatically generated shot curve ensures optimum filling during the first injection phase with shorter cycle times. Continuous Monitoring of Suction Strength and the State of the Filters The vacuum level and suction strength can be tailored to the component and the particular process. In addition, cyclical testing provides immediate information about the current condition of the filters which results in pro-active maintenance. Automated processes also provide information about any leakage around the die and the installed piping. Easy Handling due to Central Operation All functions and parameters of the SmartVac system can be set through the control system of the die casting machine. Just like the rest of the settings, they are saved in the die program. This leads to accurate and fast production changes and results in an increase in productivity. Integrated Data Acquisition for Easy Documentation and Traceability Process parameters and process data are acquired directly in the control system of the die casting machine. As a result, vacuum pressure values can be easily saved and assigned to a particular component at any time without any difficulty. Similarly, the vacuum pressure values can be displayed on the shot and diagnosis diagram. In order to show long-term performance, the corresponding values can also be added to the trend data. 18 INTEGRATED CELL Peripheral equipment for Evolution & Carat

19 Technical data SmartVac 400/ / / / / / /400 Volumetric capacity of the vacuum tank 400 l 500 l 600 l 750 l 1000 l 1500 l 2000 l Vacuum pump (Busch) 100 m³/h 100 m³/h 160 m³/h 200 m³/h 250 m³/h 2*160 m³/h 2*200 m³/h Installed power 2.7 kw 2.7 kw 3.0 kw 4.0 kw 5.5 kw 6 kw 8 kw Shot sleeve evacuation unit Die evacuation unit Control system Datanet Datanet Datanet Datanet Datanet Datanet Datanet Interface to DCM x x x x x x x Monitored die evacuation channels max 4 max 4 max 4 max 4 max 4 max 4 max 4 Controlling / Monitoring of chill vents x x x x x x x Controlling / Monitoring of hydraulic die valves x x x x x x x Controlling / Monitoring of electric die valves x x x x x x x Profile monitoring per evacuation channel x x x x x x x Monitoring of contamination per evacuation channel x x x x x x x Alarm handling x x x x x x x Archiving of production data x x x x x x x Optimizing of 1 st phase on the DCM x x x x x x x Piping between vacuum generator and evacuation units on the DCM x x x x x x x Options Controlling / Monitoring of mechanic die valves o o o o o o o Die evacuation unit 2 o o o o o o o Die evacuation unit 3 o o o o o o o Die evacuation unit 4 o o o o o o o Ejector box evacuation unit o o o o o o o Larger vacuum pump o o o o o o o Miscellaneous Die valves Area of application Carat 105 Carat 130/140 Carat 160/180 Carat 200/220 Carat 250/280 Carat 320/350 Carat 400/440 x inclusive o Option Not available Technical data to change without notice INTEGRATED CELL Peripheral equipment for Evolution & Carat 19

20 DC en 0916 Bühler AG CH-9240 Uzwil, Switzerland T F die-casting@buhlergroup.com www buhlergroup.com/die-casting

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