Automated and individual cooling solutions for your die-casting systems
The quality of the final results is always the key focus, regardless of whether you operate or manufacture aluminium casting systems (die casting, gravity die casting). To achieve this, a precisely adapted cooling system plays an important role. Bürkert offers state-of-the-art technologies for the closed-loop control of cooling media. We cover all required levels of complexity – from the delivery of individual valves, actuators and sensors to compact and automated system solutions and complete media cabinets.
Fluctuating quality and poor reproducibility
A correctly configured coolant circuit is crucial for the quality of the end products, whether you are developing a new aluminium casting plant or optimising an existing one. In each case, fluidics expertise is required. In conventional solutions, the flow rate of the cooling water is set manually. This means the tempering process is difficult to reproduce and can lead to defective end products.
Media cabinet
Tool
Close form
Filling
Maintain pressure/holding pressure
Withdrawal
Since there is no digital connection, an automatic production process is not possible. As a result, errors in the process are not detected in time. If these occur in the first process step, they cannot be corrected immediately and influence subsequent steps. The documentation of the process data is also incorrect.
Errors in the process are reproduced – rejects are the result
The manual setting of the cooling parameters has several disadvantages: It is not possible to control the functionalities of the individual water sections; an alternating inlet pressure is not taken into account. This leads to changed coolant flows, which in turn impair the quality of the end products. In addition, errors can occur during operation. Late error detection results in dead times until optimum product quality is achieved. These disadvantages have a negative effect on the OEE characteristic value.
Pressure fluctuation during water extraction and deposits in the tool – two causes of flow fluctuations in the individual cooling sections
In the event of configuration and shape changes, the cooling and thus the flow values must be reset. With manual control of the cooling parameters, multiple tests are required until the settings are correct. This takes up additional time and produces rejects.
Setting up the cooling section when changing tools
Flexible and compact
Cooling aluminium die-casting systems requires special system expertise and a broad product portfolio that allows a wide variety of configurations. Bürkert provides you with both, whether you work with air, water or mixed cooling systems. A digital and automated cooling system provides you with many advantages: You can precisely control and reproduce the coolant cycle, optimize the entire temperature control process with the help of diagnostic information, adjust your processes promptly and track your process data at any time.
Temperature sensor
Temperature sensor
Flow sensor
Ultrasonic sensor
Electromotive actuator
Pneumatic actuator
Manual actuator
Single channel solution
Multi-channel solution
Suitable for water cooling
Suitable for air cooling
From a simple cooling section to a complete media cabinet
We plan and implement complete and compact media cabinets for you according to your needs. These are equipped with the corresponding actuators, sensors and future-proof interfaces in line with your requirements. Bürkert is at your side as a reliable partner at all times, from advice through planning, installation and start-up to maintenance.
Water cooling Air cooling Water and air cooling
Thanks to our comprehensive product portfolio, we can take into account all your requirements and specifications and offer you a tailor-made cooling solution.
Thanks to the digital connection of the cooling sections, the cooling parameters can be taken directly from the CAD/CFD simulation. This reduces the amount of start-up work while at the same time manufacturing products of the highest quality right from the start.
The ready-to-install Bürkert system solution enables digital communication. This enables you to reliably reproduce your processes.
Due to the digitalised cooling systems, individual process steps are analysed and corrected automatically if errors occur. This reduces dead times and rejects and increases overall equipment effectiveness (OEE).
Via digitalisation of the coolant circuits, you can document every single process step. If errors occur, you can track them. In addition, you can prove your flawless processes to your customers.
The ready-to-install Bürkert solution minimises the amount of assembly work for the piping of the complete system. In addition, thanks to the maintenance-friendly construction, you can quickly replace single components for servicing purposes.
The modular and compact construction of the Bürkert systems leaves room for individual configurations, but remains compact and requires less space than conventional systems. In the case of multi-channel versions, we configure the system precisely to your specific width/station.
Reduced cycle time and associated hourly rate savings
The conventional solution is based on pure air cooling and optional minimum quantity mixed cooling. The cooling and production times are too long and the energy costs too high. With the Bürkert solution you can reduce the cycle time by up to 15%. We show you the benefits of this in the calculation example.
Conventional solution Bürkert solution
150 producing machines with a running time per day of 16 h and an
hourly rate of €30.00
Reduction in cycle time per machine by 15% = at least €4.50
€2,160,000 saving a year (calculated with a saving per hour of €675, at
16 h a day (€10,800) and 200 days)
Reducing the cycle time per machine by 15% results in savings of €2,160,000 per year. With assumed costs of €3,450,000 for the control cabinets for all 150 machines, the payback period is therefore 18 months.
Further application examples of our modular process control platform:
