Plunger system for die casting machine and casting method

Abstract

To provide a plunger system and a casting method for a die casting machine.SOLUTION: A casting plunger system for a die casting machine comprises: a stationary system component (1); a system component (2) having a casting plunger (3), a casing plunger rod (4), and a rod driving unit (5) and moved with respect to the stationary system component during each casing cycle for introducing a molten material into a casing mold, and configured to be reduced in speed at the end of a cast filling stage of the casting cycle under the influence of pressure applied to the molten material. The casting method is for a die casing machine having such a plunger system.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a casting plunger system for a die casting machine comprising a stationary system part and a system part which moves relative to the stationary system part in each casting cycle for introducing molten material into a casting mold, the system part having a casting plunger, a casting plunger rod and a rod drive unit, the system part being configured to decelerate at the end of the mold filling phase of the casting cycle under the effect of pressure on the molten material, and a casting method for a die casting machine having such a plunger system. [Background technology]

[0002] This type of plunger system and the associated casting method are generally known for use in die casting machines, in particular for die casting of metal parts. Each casting cycle usually consists of a pre-filling phase, during which the molten material moves or advances to the inlet of the casting mold, a mould filling phase, during which the molten material is forced into the mould, and a pressure holding phase, during which a holding pressure is applied to the molten material in the mould via the plunger. The molten material is conveyed into the mould by a corresponding melt transporting movement of the moving system parts relative to the stationary system parts of the plunger system. The stationary system parts in this case are understood to be parts of the plunger system that are held stationary, for example, in the associated mechanical structure of the die casting machine, and the moving system parts are those parts of the plunger system that move relative to the stationary system parts for this melt transport, i.e. all components of the plunger system that are moved and slowed down at the end of the mould filling phase. During this slowing down process at the end of the mould filling phase, the forward movement of the moving system parts is completely or at least largely braked to compress the melt into the mould. The remaining forward movement or some springback or oscillatory movement dissipates at the latest during the next so-called pressure hold phase, during which the moving system parts come to a complete stop if they have not already done so at the end of the mold filling phase.

[0003] The system parts to be moved usually include a plunger, a plunger rod to the front end of which the plunger is connected, and a rod drive unit driving the plunger rod for transport of the molten material by the plunger, typically comprising a drive piston and a plunger joint, via which the plunger rod is connected to the drive piston at the opposite end of the plunger. The drive piston is usually considered to be part of a so-called injection unit, which designates the driving part of the plunger system. The plunger and the plunger rod are usually considered to be part of a so-called casting tool, which refers to the driven part of the plunger system. As a further part of the injection unit, optionally a so-called multiplier unit or pressure conversion unit may be connected to the drive piston, which serves to provide a holding pressure in the pressure holding phase. The stationary system parts of the plunger system include in particular components that serve to guide the movement of the components of the system parts to be moved, such as a casting cylinder in which the drive piston is guided, and a casting chamber body, which defines, for example, a cylindrical casting chamber in which the melt is initially present and in which the plunger moves.

[0004] At the end of the mold filling stage, the moving system parts are braked by the molten material filling the mold until the forward movement stops relatively abruptly, completely or largely, creating a so-called first pressure peak for the molten material in the mold. This first pressure peak is important for the first compression of the molten material inside the mold, especially in areas of the mold or resulting casting that are relatively far from the insertion area where the molten material enters the mold. The pressure multiplication in the pressure holding stage is often not effective enough by itself due to technically induced time delays and early melt solidification. Thus, for example, in small and medium-sized cold-chamber type die casting machines, the typical mold filling time, i.e. the duration of the mold filling stage, is in the range of 10 to 15 milliseconds, and in some cases, by design, the pressure multiplication effect is delayed by 15 to 35 milliseconds in the holding stage compared to the end of the mold filling stage.

[0005] Conventionally, conflicting process objectives are taken into account with regard to the first pressure peak in the casting mold. On the one hand, the first pressure peak must be high enough to achieve a proper initial compaction of the molten material in the casting mold. On the other hand, a too high first pressure peak in the casting mold causes so-called over-injection, which means that the melt escapes over the edge of the mold at the mold parting surface, i.e. the surface separating the moving and stationary mold halves, causing the formation of undesirable flash and the need for further mechanical processing thereafter. Conventionally, the observation of these process objectives with regard to the first pressure peak takes into account that a specialized speed profile is predefined for the development of the speed of the plunger, and thus of the other components of the moved system parts of the plunger system, during the entire casting cycle, in particular at the time of the mold filling phase. However, in order to select the optimal plunger speed, especially during the mold filling phase, additional process parameters must be taken into account, such as the flow behavior of the molten material in the casting chamber, optimization of the duration of the mold filling phase, minimization of air disturbances and mold wear, as well as the geometry of the mold, the flow resistance of the molten material and the performance of the injection unit as a related part in driving the plunger system.

[0006] According to US Pat. No. 5,399,523, a casting plunger system is defined with a plunger joint with integrated hydraulic damping for a rod drive unit, comprising a damping chamber with a damping piston displaceable therein and a spring-loaded control piston which can move further by inertial forces at the end of the casting filling phase after deceleration of the plunger, in the case of damping an opening which travels between the damping chamber and the storage chamber opens and which otherwise blocks them.

[0007] Patent document 2 discloses a plunger system in which a plunger joint has a pressure chamber containing an explosive medium that can be exploded during the transition from the pre-filling stage to the mold filling stage in order to accelerate the advancement of the plunger rod and plunger relative to the rod drive unit for execution of the mold filling stage.

[0008] US Patent No. 5,399,633 discloses a casting plunger system with a hydraulic two-stroke casting drive for one pressure piston and another universal piston, and associated valve control using fast controllable servo proportional valves to adjust the amount of hydraulic medium required to act on each piston in a mutually coordinated manner.

[0009] US Patent No. 5,393,633 discloses a cast plunger system having a hollow formed cast piston and a cast piston damping arrangement between the piston rod and the cast piston, which allows the piston rod to extend partially into the hollow cast piston and move with the inner piston when decelerated simultaneously with the cast piston at the end of the mold filling stage. [Prior art documents] [Patent documents]

[0010] [Patent Document 1] German Patent No. 3433121 [Patent Document 2] Japanese Patent Application Publication No. 08-300134 [Patent Document 3] DE 4218556 A1 [Patent Document 4] German Patent No. 2833063 Summary of the Invention [Problem to be solved by the invention]

[0011] The present invention is based on the technical problem of providing a casting plunger system of the type cited at the beginning, which offers advantages in the execution of the casting process compared to the above-mentioned prior art in terms of achieving a high quality of the produced castings, as well as a casting method for a die casting machine equipped with such a plunger system. [Means for solving the problem]

[0012] The invention achieves this object by providing a plunger system having the features of claim 1 and a casting method having the features of claim 10. Advantageous refinements of the invention are set out in the dependent claims.

[0013] According to one aspect of the invention, the moved system part has a mass that can be variably adjusted between different casting cycles. Here, variably adjustable mass should be understood to mean the so-called solid mass, i.e. the mass of the rigid body, of the moved system part. This means that the mass of possibly present moved gases and fluids (such as hydraulic fluids) is not considered as part of this variably adjustable mass of the moved system part. A change in this mass therefore requires a change in the solid mass, but the final change in the mass of the fluid or gas is not taken into account for this purpose. In most cases, the mass of the moved system part corresponds substantially to the sum of the masses of the casting piston, the casting piston rod and the drive rod unit. According to a further aspect of the invention, which may be provided as an alternative to the above-mentioned aspect of the invention or in addition to the above-mentioned aspect of the invention, the moved system part consists of the moved main system part and an additional mass unit arranged to be movable relative to the main system part and configured to slow down with a predefinable delay time later than the main system part, i.e. to completely or largely stop its forward movement, at the end of the mould filling phase of the casting cycle. Here too, it should be understood that the added mass unit means one or more solid masses, i.e. rigid or solid masses, while any fluid or gas mass is not taken into account for this purpose. For convenience, the solid mass is also abbreviated to mass below.

[0014] A common feature of both inventive aspects is that the deceleration of the moved system part at the end of the mold filling phase, independent of the speed of the plunger or the speed of the moved system part, allows for a change in the momentum inherent to the moved system part before the end of the mold filling phase acting on the molten material in the casting mold. Since momentum is defined in a known manner as the product of mass and velocity and the solid mass of the moved system part can be variably adjusted during different casting cycles, therefore in the above mentioned first inventive aspect, the deceleration of the moved system part at the end of the mold filling phase of each casting cycle makes it possible to variably adjust the momentum of the moved system part acting on the molten material in the casting mold without changing the speed profile of the moved system part during the mold filling phase for different casting cycles. According to another aspect of the invention, at the end of the mold filling phase, the effect of the momentum of the moved system parts on the molten material in the casting mold can have its time evolution modified for each casting cycle in that the additional mass units are braked slower than the main system parts and accordingly the momentum effect imparted by the additional mass units to the molten material in the casting mold acts with a corresponding time delay relative to the momentum effect due to the deceleration of the moved main system parts.

[0015] It has been found that the effect of the momentum of the moved system parts, caused by the deceleration of the moved system parts at the end of the mold filling phase of each casting cycle, on the molten material present in particular in the casting mold, determines the first pressure peak of the molten material in the casting mold and therefore the first compression of the casting due to the hardening of the molten material in the casting mold, and accordingly determines or in any case substantially influences the characteristics or quality of the casting. The speed of the plunger does not have to be changed for this variable change and therefore does not have to be changed for the optimization of the momentum effect of the moved system parts on the molten material in the casting mold, and can therefore be optimized in the conventional manner with respect to other criteria, in particular the flow behavior of the molten material in its transport to and into the casting mold, as well as minimal air disturbance, minimal mold wear and short mold filling times.

[0016] The plunger system according to the invention thus allows optimizing the casting process for each produced casting, in particular with regard to casting quality and / or economy, by variably adjusting the momentum effect of the moved system parts on the molten material in the casting mould at the end of the mould filling phase, independently of the development of the plunger speed during the mould filling phase. In other words, the casting method according to the invention makes it possible to optimise both the casting process and thus the quality of the produced casting, by optimising the speed profile of the plunger during the casting cycle or, independently of this, by optimising the momentum effect of the moved system parts of the plunger system on the molten material in the casting mould at the end of the mould filling phase.

[0017] The same applies to a casting method according to the invention, which is suitable for a die casting machine equipped with a casting plunger system according to the invention, by which at least one casting parameter of each casting cycle is detected, which preferably substantially determines, co-determines and / or indicates the quality of the produced casting, and depending on the detected at least one casting parameter the mass of the moved system parts and / or the delay time of the relatively movably arranged additional mass unit can be variably adjusted for one or several future casting cycles.

[0018] In an advantageous embodiment, the plunger system comprises a control unit configured to determine an optimal mass of the moved system part and / or an optimal delay time of the additional mass unit arranged movably relative to the main system part to be set for the impending casting cycle or cycles, preferably by evaluation of the actual values ​​of one or more casting parameters detected by sensors or the like during one or more previous casting cycles, in particular casting parameters known by a person skilled in the art to influence or represent the quality of the produced castings and / or the effectiveness of the casting process. In this way, the control unit can suitably iteratively and / or automatically optimize the casting process or cycles using previously performed computer simulations.

[0019] In a refinement of the invention, the plunger system comprises one or more additional masses, each of which is adapted to be releasably attached to the system part to be moved and which in the attached state form a component of the system part to be moved. The mass and the resulting momentum of the system part to be moved acting on the molten material in the casting mould at the end of the mould filling stage may thus be variably selected by selecting one or more of these predefined additional masses and by releasably attaching the selected one or more additional masses to the system part to be moved for each casting cycle. The additional masses may form the aforementioned additional mass unit when they are arranged to be movable relative to the main system part. Alternatively, the additional masses may be additional masses arranged releasably and immovably on the other system parts to be moved.

[0020] In one embodiment of the invention, a number of additional masses are provided, at least two of which have different masses. This provides good conditions for minimizing the number of such additional masses to be provided in order to be able to variably set the mass of the system part to be moved within a range of predefinable values. For example, the additional masses for this purpose may differ in mass in a binary manner, i.e. by a power of two, or alternatively in a different graduated distribution. Alternatively, the additional masses may for example each have the same mass, i.e. for example be manufactured as an identical part. In a corresponding embodiment, the plunger system comprises a control unit configured to automatically select the respective additional masses to be attached to the system part to be moved. For this selection, the control unit preferably uses knowledge of casting parameters related to the casting process for the impending casting cycle and / or one or more preceding casting cycles.

[0021] In one embodiment of the present invention, the stationary system part has an additional mass storage unit for storing and providing one or more additional masses. In this way, the additional masses can be provided very easily for use in the system part to be moved. The additional mass selected for this use is taken from the storage unit of the stationary system part and connected to the system part to be moved. Alternatively, the additional mass or masses may be provided outside the plunger system or separately from the plunger system, for example at another location of the mechanical structure of the die casting machine in which the plunger system is provided.

[0022] In one embodiment of the invention, the plunger system comprises an additional mass handling unit configured to automatically attach and detach the additional mass to and from the system part to be moved, which may for example be implemented by a fully automated handling robot or alternatively by a semi-automatic and partly user-operated handling device.

[0023] In a refinement of the invention, the plunger system comprises a set of casting plungers with different predefined masses, which are adapted to be used interchangeably as plungers of the system parts to be moved, in this way the mass of the system parts to be moved can be set variably between different casting cycles, the pistons differing in mass by predefined mass increments. In order to achieve an optimal momentum of the plunger system at the end of the mould filling stage, in this case the most suitable plunger from the set of plungers with different predefined masses may be selected and used as the plunger of the system parts to be moved. The mass increments may be predefined in any desired way, for example all of the same size or at least some of them of different sizes.

[0024] In order to be able to keep the casting chamber unchanged, it is preferred that the plunger in this variant of the embodiment of the invention has the same outer diameter. The choice of suitable materials for the plunger is also relatively limited due to the requirements imposed regarding strength and direct melt contact, in which case the generally achievable mass change of the plunger is correspondingly limited, therefore making this embodiment of the invention suitable for smaller mass changes.

[0025] In a refinement of the invention, the plunger system comprises a set of multiple casting plunger rods with different predefined masses, configured for interchangeable use as plunger rods of the system part to be moved, the plunger rods differing in mass by predefined mass increments. In order to achieve an optimal momentum of the plunger system at the end of the mould filling stage, in this case the most suitable plunger rod is selected from the set of multiple plunger rods with different predefined masses and used as the plunger rod of the system part to be moved. The mass increments may be predefined in any desired way, for example all of the same size or at least some of them of different sizes.

[0026] In an advantageous embodiment, the casting plunger rods with different predefined masses are configured for use with the same casting plunger or, in any case, casting plungers of the same outer diameter, and preferably also for use with the same casting chamber, so that by exchanging the casting plunger rods the mass of the system parts to be moved can be changed in the desired way, without requiring different casting chambers or casting plungers of different outer diameters. In the case of plunger rods of different weights, in this case preferably the same outer diameter is selected over the entire insertion depth in the casting chamber. The different masses can be provided, for example, by using materials of different weights and / or by different designs of the plunger rods, in particular with regard to their outer diameters, in the axial region outside the immersion depth in the casting chamber. By insertion depth is meant here the axial region of the plunger rod in which it can be maximally immersed in the casting chamber, i.e. when the plunger is maximally advanced at the end of the pressure hold phase. Although the plunger rod typically constitutes a relatively easily replaceable part of the plunger system, this embodiment of the invention may be particularly advantageous in many applications since it contributes a significant proportion to the total mass of the system parts being moved.

[0027] In a refinement of the invention, the plunger system comprises a set of multiple cast plunger joints with different predefined masses, which joints are configured for interchangeable use as cast plunger joints of the rod drive units of the system parts to be moved, the plunger joints differing in their mass by predefined mass increments. In order to achieve an optimal momentum of the plunger system at the end of the mould filling stage, in this case the most suitable plunger joint from the set of multiple plunger joints with different predefined masses may be selected and used as the plunger joint of the system parts to be moved. The mass increments may be predefined in any desired way, for example all of the same size or at least some of them of different sizes. The use of plunger joints of different masses does not require modification of the casting chamber.

[0028] In a refinement of the invention, the plunger system comprises a set of cast plunger drive pistons with different predefined masses, which are configured for interchangeable use as cast plunger drive pistons of the rod drive units of the system parts to be moved, the plunger drive pistons differing in mass by predefined mass increments. In order to achieve an optimal momentum of the plunger system at the end of the mould filling stage, the most suitable plunger drive piston from the set of plunger drive pistons with different predefined masses may then be selected and used as the plunger drive piston of the system parts to be moved. The mass increments may be predefined in any way, for example all of the same size or at least some of them of different size. Using plunger drive pistons of different masses does not require modification of the casting chamber.

[0029] In a refinement of the invention, the additional mass of the moved system part, which is movably arranged with respect to the main system part, comprises an additional mass which is slidably movable on the moved main system part between a start position and an end position, the start position being defined by an initial end stop on the moved main system part and / or the end position being defined by an impact end stop on the moved main system part, the additional mass unit in this case initially moving from the start position with a substantially unchanged speed due to its mass inertia, after decelerating the moved main system part at the end of the mould filling phase, and then, on reaching the impact end stop, slowing down in order to develop its momentum effect with a corresponding delay on the main system part and, via it, on the molten material in the mould.

[0030] It is understood that the relatively movable additional mass may comprise a number of such individual additional masses, each having an associated, preferably variable, sliding stroke, depending on the requirements and application. In corresponding system embodiments, the sliding strokes of the slidably movable additional masses may be different, so that they exert their momentum effect on the molten material in the casting mould at different times at the end of the mould filling stage, thereby allowing a large variability in the time development of the momentum effect of the moved system parts on the molten material in the mould.

[0031] In one embodiment of the invention, the initial end stop is adjustable on the main system part that is moved. Alternatively or additionally, the impact end stop is adjustable on the main system part that is moved. These two measures each allow adjustment of the sliding stroke of the added mass unit on the main system part that is moved, and therefore the delay time during which the added mass unit is decelerated slower than the main system part at the end of the mold filling phase.

[0032] In a variant of the advantageous embodiment, it may further be provided that the sliding stroke of the additional mass unit may be variably adjusted, either manually or automatically, depending on the casting speed at which the system parts moved before decelerating during the mould filling phase are moved, so that the delay time of the additional mass unit may be kept substantially constant, if necessary, for example when the casting speed is changed to adapt to other circumstances, such as the use of a different mould and / or a different casting molten material.

[0033] In one embodiment of the invention, the plunger system comprises a locking unit for releasably locking the additional mass in a start position or an end position or in a predefined locking position between the start and end positions. Activation of the locking unit locks the additional mass in the respective position, thereby making it an additional mass immovably connected to the moved main system part and which develops its momentum effect on the molten material in the casting mould simultaneously with the other moved system parts at the end of the mould filling phase. After this locking is released, the additional mass may again function as an additional mass acting on the molten material in the casting mould with a delay relative to the other moved system parts.

[0034] Advantageous embodiments of the invention are depicted in the drawings. These and further embodiments of the invention are explained in more detail below. [Brief description of the drawings]

[0035] [Figure 1] FIG. 1 shows a schematic side view of a plunger system according to the present invention having an additional mass fixed to a plunger drive piston and associated casting chamber and mold for a die casting machine. [Diagram 2] FIG. 2 shows a view corresponding to FIG. 1, but without the casting chamber and the casting mould, of a variant of the embodiment of the plunger system according to the invention having an additional mass fixed to the plunger joint. [Diagram 3] FIG. 3 shows a view corresponding to FIG. 2 of a variant of the embodiment of the plunger system according to the invention having an additional mass fixed to the plunger rod. [Figure 4] FIG. 4 shows a view corresponding to FIG. 2 of a variant of the embodiment of the plunger system according to the invention having an optional additional mass which can be additionally connected. [Diagram 5] FIG. 5 shows a view corresponding to FIG. 2 of a modified embodiment of the plunger system according to the present invention having an additional mass body arranged so as to be slidably movable. [Figure 6]FIG. 6 shows a view corresponding to FIG. 2 for a variant of the embodiment of the plunger system according to the invention, having a set of multiple plungers and / or plunger rods and / or plunger joints and / or plunger drive pistons of different predefined masses. [Figure 7] FIG. 7 shows a schematic flow diagram illustrating the steps of interest in an embodiment of a casting method according to the invention. [Figure 8] FIG. 8 is a characteristic curve diagram illustrating the evolution of the melt pressure in the casting mold over time during the casting process for the different performance variations of a casting method according to the invention and a casting method not according to the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] 1 shows a schematic representation of a casting plunger system according to the invention for a die casting machine, which comprises a stationary system part 1 and a moving system part 2. The stationary system part 1 comprises, for example as shown, a casting chamber 12 and a casting plunger drive cylinder 13, the latter often simply known as a casting cylinder. The casting chamber 12 usually opens into a casting mould 14 formed by a stationary mould half and a mobile mould half of the die casting machine. The moving system part 2 is movable relative to the stationary system part 1 in order to introduce molten material into the casting mould 14 in each casting cycle, and to this end comprises a casting plunger 3, a casting plunger rod 4 and a rod drive 5, and is arranged to decelerate at the end of the mould filling phase of the casting cycle under the effect of pressure on the molten material.

[0037] The plunger 3 is arranged fluid-tight and axially displaceable in, for example, a cylindrical casting chamber 12. In the illustrated example, a plunger rod 4 supports the plunger 3 in its front end surface area and is connected in its rear end surface area to a rod drive unit 5, in particular to a plunger joint 9 of the rod drive unit 5. In the illustrated example, the plunger joint 9 connects the plunger rod 4 to a front end surface area of ​​a plunger drive piston 10 of the rod drive unit 5, which is guided axially displaceable in a plunger drive cylinder 13. Optionally, the plunger drive piston 10 is connected to a pressure multiplier unit (not shown).

[0038] According to the invention, the moved system part 2 has a solid mass that is variably adjustable between the different casting cycles and / or, as in the exemplary embodiment of FIG. 5, comprises a main system part 2a to be moved and an additional solid mass unit Z movably arranged relative to it and configured to decelerate with a predetermined delay time relative to the main system part 2a at the end of the mold filling phase of the casting cycle. E It consists of:

[0039] In a corresponding embodiment, the plunger system according to the invention comprises one or more additional solid masses, each of which is adapted to be releasably attached to the system part 2 to be moved and which in the attached state form a rigidly connected component of the system part 2 to be moved. Figure 1 shows an embodiment variant in this respect, in which such an additional mass ZK is in particular releasably attached to the plunger drive piston 10 of the system part 2 to be moved. Figure 2 shows an embodiment variant in this respect, in which such an additional mass ZK is in particular releasably attached to the plunger joint 9 of the system part 2 to be moved. Figure 3 shows an embodiment variant in this respect, in which such an additional mass ZK is in particular releasably attached to the plunger rod 4 of the system part 2 to be moved. In this case, it is understood that the additional mass ZK is arranged in an axial part of the plunger rod 4 outside or behind the immersion depth by the front rod part of the plunger rod 4 being immersed to the maximum in the casting chamber 12 in order to advance the plunger 3, so that the additional mass ZK does not hinder the forward movement of the front immersion depth part of the plunger rod 4 into the casting chamber 12. FIG. 4 in this respect shows a variant of the embodiment in which several such additional masses ZK1, ZK2, ZK3 may be optionally releasably attached to the system part 2 to be moved, for example the plunger joint 9 or the plunger drive piston 10, FIG. 4 shows a situation in which only the first additional mass ZK1 is releasably attached to the system part 2 to be moved, here in particular the plunger joint 9. It is preferably provided that the assembly and disassembly of one or more additional masses ZK or ZK1, ZK2, ... can be achieved without tools and / or using a quick-change system or a quick-clamping system.

[0040] In a variant of such an embodiment with a number of additional masses ZK1, ZK2, ... which can be releasably attached to the system part 2 to be moved, it can be advantageous if at least two of the number of additional masses ZK1, ZK2, ... have different masses. For example, these additional masses ZK1, ZK2, ... may differ in mass by a power of two, i.e. the next heavier additional mass may have twice the mass of the next lighter additional mass. With regard to such a doubling of the mass of the additional masses ZK1, ZK2, ... any integer multiple of the minimum mass of the lightest additional mass may be set, so that a smaller number of additional masses has to be provided compared to the total mass of all additional masses ZK1, ZK2, ...

[0041] In a corresponding embodiment, as in the exemplary embodiment of Fig. 4, the stationary system part 1 comprises an additional mass storage unit 6 for storing and providing the additional masses ZK or ZK1, ZK2, .... For example, Fig. 4 shows an embodiment in which the additional masses ZK1, ZK2, ... are removably suspended on an additional mass holder 6a serving as the additional mass storage unit 6, which is then arranged on the stationary system part 1, for example on the plunger drive cylinder 13, or alternatively on another stationary fixed part of the respective die casting machine. The additional masses ZK1, ZK2, ... thus stored can then be taken out of the additional mass storage unit 6, individually or in any combination, as required, and releasably attached to the system part 2 to be moved in order to carry out a casting cycle with the desired total mass of the system part 2 to be moved.

[0042] In a corresponding embodiment, the plunger system comprises an additional mass handling unit 7 configured to automatically attach and detach each additional mass ZK or ZK1, ZK2, ... to and from the system part 2 to be moved. Such an additional mass handling unit 7 is shown as a block diagram in FIG. 4 in the exemplary embodiment shown there. It may comprise, for example, a conventional handling robot specially configured to carry out the necessary handling measures. Alternatively, the additional masses ZK or ZK1, ZK2, ... may be attached and detached to and from the system part 2 to be moved by a corresponding operator.

[0043] In a corresponding embodiment, the plunger system according to the invention, as shown in FIG. 6, comprises a set of multiple cast plungers 31-3, shown as a block diagram in FIG. 6, having different predefined masses, which differ by predefined mass increments and are configured for interchangeable use as plungers 3 of the system part 2 to be moved. n1 and / or A set of multiple cast plunger rods 41-4, shown as a block diagram in FIG. 6, having different predefined masses, which differ by predefined mass increments, and configured for interchangeable use as plunger rods 4 of the system components 2 to be moved. n2 and / or A set of multiple cast plunger joints 91-9, shown as a block diagram in FIG. 6, having different predefined masses, which differ by predefined mass increments, and which are configured for interchangeable use as plunger joints 9 of rod drive units 5 of system components 2 to be moved. n3 and / or A set of multiple cast plunger drive pistons 101-10, shown as a block diagram in FIG. 6, having different predefined masses, which differ by predefined mass increments, and configured for interchangeable use as plunger drive pistons 10 of rod drive units 5 of system components 2 to be moved. n4 Equipped with.

[0044] Depending on the application and the desired total mass of the system parts 2 to be moved, the plungers 3 actually used may be different masses of the current plungers 31-3. n1 and / or the plunger rod 4 actually used may be selected from the number n1 of plunger rods 41-4 having different masses. n2 and / or the plunger joint 9 actually used may be selected from the number n2 of plunger joints 91-9 having different masses. n3 and / or the plunger drive piston 10 actually used may be selected from the number n3 of plunger drive pistons 101-10 having different masses. n4 Depending on the system design, the number n4 of plungers 31-3 may be selected. n1 , plunger rod 41-4 n2 , plunger fitting 91-9 n3 , and plunger drive piston 101-10 n4 Of the four sets, all four sets may be present for a given plunger system, only one of the four sets may be present, or any two or three of the four sets may be provided.

[0045] In this type of embodiment of the invention, the mass of the system part 2 to be moved may be variably adjusted between different casting cycles by selecting different plungers and / or different plunger rods and / or different plunger joints and / or different plunger drive pistons. If required, furthermore, releasable attachment of one or more additional masses to the system part 2 to be moved may be provided, as shown by the additional mass ZK releasably attached to the plunger rod 4 in the example shown in FIG. 6. Also, this type of embodiment may be provided, if required, by using the above-mentioned additional mass ZK movably arranged with respect to the main system part 2a to be moved. E may be complemented by

[0046] Each plunger 31-3 n1 , plunger rod 41-4 n2 , plunger fitting 91-9 n3 , and plunger drive piston 101-10 n4 However, the mass increments of the different masses may be suitably predefined depending on the circumstances and requirements. Here, it is usually convenient to keep the mass increments between two components with successive masses and / or the total mass difference between the lightest and heaviest components of each set within predefined limits. This can be achieved, for example, by predefining suitable thresholds, e.g. given as percentages, such that the mass increments of the sets of components differ at a maximum and / or the mass of the heaviest component of each set is at a maximum greater than the mass of the lightest component of the set.

[0047] In a corresponding embodiment, an additional mass Z is arranged movably relative to the main system component 2a. Ecomprises an additional mass ZM arranged on a main system part 2a that is slidably moved between a start position and an end position, the start position being defined by an initial end stop IA on the main system part 2a that is moved and / or the end position being defined by an impact end stop AA on the main system part 2a that is moved. Figure 5 shows a corresponding exemplary embodiment having both an initial end stop IA and an impact end stop AA on the main system part 2a that is moved.

[0048] In an advantageous embodiment, at least the initial end stop IA or the impact end stop AA is adjustable on the main system part 2a to be moved, and an adjustability of both end stops IA, AA may also be provided. The end stops may be adjusted manually, for example by a manually actuated threaded spindle, or automatically by a corresponding actuator mechanism, as required. In the exemplary embodiment of Fig. 5, the impact end stop AA is provided on the plunger joint 9, while the initial end stop IA is axially adjustably provided on the plunger drive piston 10.

[0049] The additional mass ZM may be slidably moved relative to the rest of the moved system part, i.e. relative to the moved main system part 2a, by a sliding stroke or stroke H corresponding to the axial distance between the start and end positions. If the additional mass ZM and the moved main system part 2a together move with a predefined forward speed during the mould filling phase and at the end of the mould filling phase the moved main system part 2a slows down, the slidably movable additional mass ZM initially maintains this forward speed until it has travelled the stroke H from the start position to the end position and then slows down at the impact end stop AA. In this way, at the end of the mould filling phase of the casting cycle the additional mass ZM slows down a predefined delay time later than the main system part 2a, which time is the stroke H divided by the forward speed of the moved system part 2 at the end of the mould filling phase just before the moved main system part 2a slows down.

[0050] If at least one of the two end stops IA, AA is adjustable, this means a corresponding adjustment of the stroke H, so that, in accordance with the above-mentioned functional correlation with the stroke H, the delay time during which the additional mass ZM slows down behind the main system part 2a to be moved can be variably predefined in any desired manner, without the need to change the forward speed of the system part 2 to be moved.

[0051] In the exemplary embodiment of FIG. 5, the relatively movable additional mass unit Z E consists of only an additional mass ZM, but in an alternative embodiment, a relatively movable additional mass unit Z E comprises one or more additional masses arranged so that they can be moved in a desired manner relative to the main system component 2a to be moved. E Similarly, the additional mass Z in Figs. Kor one or more additional masses of the embodiment of additional masses ZK1, ZK2, ... of FIG. 4 are provided, which are configured to be releasably attached to the system part 2 to be moved and, in the attached state, form components of the system part 2 to be moved that are immovably connected to the remainder of the system part to be moved.

[0052] The fixedly connected attachment of an additional mass, such as one additional mass ZK in Figs. 1 to 3 or several additional masses ZK1, ZK2, ... in the exemplary embodiment of Fig. 4, provides a corresponding additional momentum transfer to the molten material at the end of the mold filling phase precisely at the time of the primary momentum transfer from the deceleration of the moved system part 2 or the moved main system part 2a, while the remaining part of the moved system part, i.e. the additional mass ZK to the main system part 2a, is not affected by the deceleration of the additional mass ZK to the main system part 2a. E The relatively movable connection of the two leads to an additional momentum transfer to the molten material at the end of the mold filling stage, which occurs a predefinable delay time later than the primary momentum transfer due to the deceleration of the moving main system part 2a.

[0053] To clarify this with a diagrammatic example, suppose that the forward speed of the moved system part 2 towards the end of the mould filling stage is 5 m / s, the fixed mass of the moved main system part 2a is 100 kg, and the additional mass unit Z E The mass of the added mass unit Z is 20 kg. E Assuming that the slide stroke H is 50 mm, the following is obtained. Then, the additional mass unit Z Eimparts an additional momentum of 20% to the melt relative to the momentum of the fixed mass of the moved main system part 2a, with this momentum transfer commencing 10 ms after the momentum transfer due to the deceleration of the moved main system part 2a. The delayed momentum transfer effect can advantageously bridge the time between the first pressure peak, which occurs 2 seconds after the momentum transfer of the fixed mass of the moved main system part at the end of the mold filling, and the action of any pressure multiplier, which typically only starts about 20 ms to 35 ms after the end of the mold filling, without the first pressure peak rising too high, avoiding overfilling the mold.

[0054] Added Mass Unit Z E The delay timing of the additional momentum transfer to the molten material imposed by the additional mass unit Z can be influenced in a targeted manner depending on the circumstances or casting parameters, in particular depending on the plunger speed and the structural casting arrangement. By adjusting the end stop as required, i.e. by adjusting the slide stroke H, the delay momentum transfer effect may be variably adjusted in order to optimize the process for successive casting cycles. Here, if desired, the additional mass unit Z E The mass of, for example, the added mass unit Z E or from a variable number of additional masses which can be arbitrarily connected relatively movably to the main system part 2a to be moved. E In this manner, the strength and / or timing of this additional momentum transferred to the molten material at the end of the mold filling stage can be tailored to achieve the desired optimum casting quality, which can be determined, for example, empirically or by computer simulation.

[0055] In a corresponding embodiment of the invention, the moved system part 2 is movable relative to the main system part 2a and is arranged to decelerate at the end of the mold filling phase of the casting cycle by a delay time that can be individually predefined slower than the main system part 2a. EEach additional mass unit Z E , in this case, the strength of the transfer of additional momentum applied to these masses, and thus to the molten material, may be established individually, as may the time of transfer of additional momentum to the molten material by their deceleration. If necessary, in a variation of this embodiment, the transfer of successive additional momentum to the molten material, which is staggered in time, may be established by successively decelerating multiple additional mass units Z E can be provided by

[0056] In an advantageous embodiment, the plunger system is adapted to lock the additional mass Z in a start position or an end position, or in a predetermined locking position between the start and end positions, as shown in the exemplary embodiment of FIG. M For example, in the embodiment of FIG. 5, the lock unit 11 is pivotally held on the plunger joint 9 and is connected to the additional mass Z M When the end position, i.e., the impact end stop AA of the plunger joint 9 is reached, the additional mass Z M The locking bar device is formed by a locking bar that engages with a corresponding bar receiver in the locking bar holder.

[0057] The lock unit 11 is an additional mass Z M After the casting process is completed, the additional mass Z M ensures that the lock is released so that the additional mass Z can return to its starting position. M The return movement of the can be optionally performed by, as in the example of FIG. 5, on the one hand, the additional mass Z M on the one hand, it may be supported by a return spring arrangement 15 which is held in a receiving portion of the plunger coupling 9 .

[0058] Figure 7 shows in a schematic flow diagram the casting method according to the invention with the method steps of interest here, for a die casting machine with a plunger system according to the invention, i.e. in an embodiment of the type shown in one of Figures 1 to 6. In a manner known per se, for carrying out each casting cycle, one or more casting parameters are detected which originate from one or more preceding casting cycles and / or are predefined for the impending casting cycle. These casting parameters are usually detected by a machine control system which is attached to the die casting machine and forms or constitutes a control unit for the plunger system. The control unit for the plunger system is known per se and is arranged to control or regulate the respective casting process.

[0059] Characteristically, in the plunger system according to the present invention, the control unit is connected to an additional mass unit Z 1 which is arranged movably relative to the main system component 2a. E , the mass of the displaced system part 2 that is optimally set for the impending casting cycle or cycles and / or the delay time that is optimally set for the impending casting cycle or cycles. Preferably, for this, the control unit evaluates the actual values ​​of one or more casting parameters detected by sensors or the like and belonging to one or more preceding casting cycles, in particular casting parameters that influence or are representative of the quality of the produced castings and / or the effectiveness of the casting process. This allows the control unit to automatically optimize the casting cycles by pure control and / or by iterative control and / or by control using previously performed computer simulations and / or by real-time control interventions during each casting process, depending on the design of the control system.

[0060] Thus, according to the method, the mass of the system part 2 to be moved and / or the additional mass unit Z movably arranged relative to it is moved for one or more future casting cycles, as shown in FIG. EThe delay time is variably adjusted in response to the detected at least one casting parameter, and the casting process is carried out with a correspondingly optimized casting process control.

[0061] In a corresponding embodiment, as part of the execution of the casting process according to the method, by means of a suitably stored algorithm, the control unit determines from the plunger position the plunger speed, i.e. the forward speed of the system part 2 to be moved, the mass of the system part 2 to be moved or the mass of the main system part 2 a to be moved, and the mass of the slidably movable additional mass unit Z E and configured to establish an associated momentum or an equivalent momentum associated with the transfer of momentum to the molten material and provide the same for further processing. This can also be used, for example, to show or depict, visually or otherwise, the determined momentum transfer effect as a measure of the compressive effect of the first pressure peak occurring in the melt at the end of the mold filling stage.

[0062] Furthermore, in a corresponding embodiment, the control unit determines the relative height of the moved system part 2 or the moved main system part 2a and the relatively movable additional mass unit Z for the desired height of the first pressure peak depending on the influencing factors present in a given die casting machine or a given plunger system. E or is configured to establish this empirically or by computer simulation using specific maps belonging to the casting to be produced. Additionally or alternatively, the control unit may be configured to determine the optimal added mass without knowing the actual pressure peaks, in this case empirically from, for example, an evaluated casting quality, in which case the plunger speed can be varied without changing the momentum effect.

[0063] In particular, the influencing factors are one or more of the following factors: preselected or actual plunger speed during the mold filling stage; Relatively movable additional mass unit Z Eand the mass of the system part 2 to be moved without the releasably attached additional masses ZK, ZK1, ..., Closing force of die-casting machine's mold closing unit, the impact area of ​​the casting and / or the gate, the weight of the casting and / or the gate, The characteristics of the casting, especially the wall thickness, The composition of the molten material, The diameter of the plunger effective within the casting chamber 12, the dimensions of the plunger drive, particularly the diameter and hydraulically effective area, the hydraulic drive pressure of the plunger drive, Parameters of the optional booster device, in particular the dimensions and hydraulically effective area of ​​the booster unit, the predefined pressure profile and pressure of the booster system, and Relatively movable additional mass unit Z E The actual value and / or the maximum possible value of the slide stroke H if present.

[0064] The control unit also determines the current relatively movable added mass unit Z E For a desired height of the first pressure peak with a known mass of , the method may be configured to determine the associated value of the slide stroke H depending on the influencing factors, or to establish this from a map created empirically or specifically by computer simulation for the casting to be produced. Again, the process may be similar if the actual pressure peak is not known, but the momentum transfer effect has been empirically assessed as good, and only the plunger speed is changed without changing the momentum transfer effect. The additional influencing factors here are the locking state of the locking unit 11, if present, i.e. the relative movable additional mass unit Z E or a relatively movable additional mass Z M may be locked by the lock unit 11 or not.

[0065] It will be appreciated that a selected change in mass of the system part 2 to be moved can be appropriately taken into account by the control unit for the overall control of the plunger system. Thus, a change in mass of the system part 2 to be moved requires a correspondingly changed drive force to accelerate the system part 2 to be moved.

[0066] The detection of the casting parameters is supported by suitable sensors, whose tasks will be easily understood by a person skilled in the art, and which may in particular include one or more of the following sensors: Fixedly connected additional masses ZK, ZK1, ... and / or relatively movable additional mass units Z E one or more limit switches for detecting the presence of Hardwired and / or wireless identification sensors for identifying the individual additional masses and / or assemblies of the plunger system, in particular the system part 2 to be moved; an acceleration sensor which is analysed together with sensor data from the casting drive system, in particular with regard to position, pressure etc., in order to determine the total mass of the system part 2 being moved; Relatively movable additional mass unit Z E a sensor for measuring the actual slide stroke H when Relatively movable additional mass unit Z E or additional mass Z M a sensor for detecting whether the is in a starting position; When the lock unit 11 is present, the relatively movable additional mass unit Z E or a relatively movable additional mass Z M A sensor that detects whether the device is in a locked state.

[0067] In the characteristic curve diagram for the exemplary embodiment, FIG. 8 shows a typical development of the internal mold pressure, i.e. the pressure pS of the molten material in the casting mold, as a function of time t during the final part of the mold filling phase and the subsequent pressure holding phase. Here, a first curve K1 (shown as a dotted line) shows a typical time development of the internal mold pressure pS of a conventional plunger system without a pressure multiplier. The plunger initially moves, for example, with an approximately constant forward speed, i.e. the filling speed, and as soon as it reaches the end of the mold filling phase at time tE, pressure builds up in the casting mold, causing a pressure rise in the casting chamber, which brakes the plunger to a standstill, i.e. the momentum of the plunger or of the moved system part of the plunger system dissipates to zero with a corresponding increase in the internal mold pressure. The liquid molten material in the mold acts to some extent like a compressible, i.e. hydraulic spring. At time tS, the moved system part of the plunger system stops for the first time and a maximum pressure value prevails in the mold, i.e. the first pressure peak. Subsequently, as is evident from the course of curve K1, post-damped oscillations of the internal mold pressure pS arise due to the corresponding damped oscillatory movements of the moved system parts of the plunger system between the compressible molten material on the one hand and the compressible hydraulic fluid in the driven casting device on the other hand.

[0068] The second curve K2 represents the time when the plunger system according to the invention is connected to an additional mass that is rigidly connected to the system part 2 to be moved, for example the additional mass Z according to FIGS. 1 to 3. K4 and the additional masses ZK1, ZK2, ... and a pressure multiplier are used. Up to time tE at the end of the mold filling phase with the initial strong pressure rise, the course of the casting process corresponds to that of the prior art according to curve K1, where again damped after-oscillations occur at the transition to the pressure hold phase. However, here, at time tS of the first pressure peak, the internal mold pressure pS is higher than in the prior art case, i.e. curve K2 is located above curve K1. Also, at time tM, the effect of the pressure multiplier starts, whereby the internal mold pressure pS reaches the desired high final value pF, which is significantly higher than the final value pK of the prior art according to the first curve K1 without a pressure multiplier. The increase in the internal mold pressure pS at the time of the first pressure peak tS is due to additional momentum transferred to the molten material in the casting mold from additional mass provided by one or more additional mass bodies ZK, ZK1, ZK2, ... fixedly connected to the moved system part 2 of the plunger system and / or is brought about by replacing the corresponding components of the moved system part 2 with functionally equivalent components having different masses, as described in Figure 6.

[0069] The third curve K3 shows an exemplary casting process using a plunger system according to the invention in an embodiment corresponding to that described above with respect to the second curve K2, but with a relatively movably arranged additional mass unit Z E There is an additional mass unit Z E develops its momentum transfer effect on the molten material at a predefined delay time later than the main system part 2a that is moved, so that the time development of the internal mold pressure pS in the exemplary embodiment according to the curve K3 is determined by the time when this delay time has elapsed and the additional mass unit Z EThe curve K3 corresponds to that of the curve K2 until the time tV when the additional mass unit Z decelerates and additionally transfers its momentum to the molten material. At this time tV, the internal mold pressure pS thus rises, and in the further course of the casting process until the end pressure pF is reached during the pressure hold phase, the associated curve K3 lies above the second curve K2 due to the corresponding additional pressure. As is evident from a comparison of the curves K2 and K3, the additional mass unit Z E is relatively movably arranged so that it is possible to provide a desired amount of pressure increase relative to the internal mold pressure pS during the time between the time tS of the first pressure peak and the start time tM of the pressure multiplication effect.

[0070] As is evident from the exemplary embodiments described above, the present invention provides an advantageous plunger system for use in die casting machines, which allows the casting process to be significantly optimized or improved compared to conventional casting processes, in particular at the end of the mold filling phase and at the transition to the pressure hold phase, thus allowing the quality of the produced casting to be improved. In particular, the transfer of momentum to the molten material can be changed by changing the mass of the system part being moved, without necessarily changing the forward speed of the system part being moved, which can favorably affect the compaction, strength, porosity and / or structure formation of the casting.

[0071] The invention allows a targeted influence on the mould filling time imposed by the forward speed of the moved system part 2, i.e. the duration of the mould filling phase, and on the pressure value of the internal mould pressure at the first pressure peak, independently of each other, because according to the invention this pressure value can be changed by the mass change of the moved system part, without changing the forward speed. The invention allows, for example, to use a plunger system with a minimum mass of the moved system part, which is in principle advantageous for achieving short mould filling times, due to the high predefinable forward speed. The mass of the moved system part can also be increased by the above-mentioned measures, if necessary, in order to achieve the desired pressure level of the first pressure peak and / or to achieve a pressure increase at a time after the first pressure peak by the delayed action of the relatively movable additional mass unit, in particular to be used as a bridging measure until the onset of the pressure multiplication effect. According to aspect (1), there is provided a casting plunger system for a die casting machine, comprising: - a static system component (1); a system part (2) movable relative to said stationary system part in each casting cycle for introducing molten material into a casting mold, said system part (2) having a casting plunger (3), a casting plunger rod (4) and a rod drive unit (5), said system part (2) being configured to decelerate at the end of a mold filling phase of a casting cycle under the effect of pressure on said molten material, the system parts that are moved have a mass that can be variably adjusted between different casting cycles, and / or a casting plunger system, characterized in that the moved system part comprises a moved main system part (2a) and an added mass unit (ZE) arranged to be movable relative to the main system part and configured to decelerate with a predefinable delay time later than the main system part at the end of the mould filling phase of the casting cycle. According to aspect (2), the device is further characterized by one or more additional masses (ZK, ZK1, ZK2, ...) configured to be releasably attached to the system part to be moved and, in the attached state, forming components of the system part to be moved. According to the aspect (3), a plurality of additional masses are provided, at least two of which have different masses. According to aspect (4), the stationary system component comprises an additional mass storage unit (6) for storing and providing one or more of the additional masses. According to aspect (5), the system is further characterized by an additional mass handling unit (7) configured to automatically attach and detach an additional mass to and from the system part to be moved. According to aspect (6), further, - a set of multiple cast plungers (31, 32, ...) with different predefined masses, which differ by predefined mass increments, and which are adapted to be used interchangeably as cast plungers of the system parts to be moved, and / or - a set of a plurality of cast plunger rods (41, 42, ...) having different predefined masses, which masses differ by predefined mass increments, and which are adapted for interchangeable use as cast plunger rods of the system parts to be moved, and / or - a set of a plurality of cast plunger couplings (91, 92, ...) having different predefined masses, which masses differ by predefined mass increments, and which are configured for interchangeable use as cast plunger couplings (9) of the rod drive units of the system parts to be moved, and / or - further characterized by a set of a plurality of cast plunger drive pistons (101, 102, ...) having different predefined masses, which differ by predefined mass increments, and which are configured for interchangeable use as cast plunger drive pistons (10) of the rod drive units of the system parts to be moved. According to aspect (7), the relatively movably arranged additional mass unit includes an additional mass (ZM) arranged on the main system component to be moved and slidably movable between a start position and an end position; The start position is further characterized by being defined by an initial endstop (IA) on the main system component being moved, and / or the end position is defined by an impact endstop (AA) on the main system component being moved. According to aspect (8), the initial end stop (IA) is adjustable on the main system part to be moved, and / or - characterized in that the impact end stop (AA) is adjustable on the main system part to be moved. According to aspect (9), the method is further characterized by a locking unit (11) for releasably locking the additional mass in the start position or in the end position or in a predefinable locking position between the start position and the end position. According to an aspect (10), there is provided a casting method for a die casting machine having the casting plunger system of any one of aspects 1 to 9, comprising: - at least one casting parameter of each casting cycle is detected; and A casting method, in which the mass of the system part to be moved and / or the delay time of an additional mass unit arranged to be relatively movably are variably adjusted for one or more future casting cycles depending on at least one detected casting parameter.

Claims

1. 1. A casting plunger system for a die casting machine, comprising: - a stationary system component (1); a system part (2) which moves in each casting cycle for introducing molten material into a casting mould relative to said stationary system part and which comprises a casting plunger (3), a casting plunger rod (4) and a rod drive unit (5), the system part (2) being adapted to decelerate at the end of the mould filling phase of the casting cycle under the effect of pressure on the molten material, the system part to be moved has a mass which can be variably adjusted between different casting cycles and the stationary system part (1) is provided with the same casting chamber for use with the variably mass-adjusted system part to be moved, and / or a casting plunger system, characterized in that the moved system part comprises a moved main system part (2a) and an additional mass unit (ZE) arranged so as to be movable relative to the main system part and configured to decelerate by a predefinable delay time slower than the main system part at the end of the mold filling phase of the casting cycle, the additional mass unit (ZE) being connected to the main system part (2a) and configured to decelerate by the predefinable delay time slower than the main system part (2a) when the main system part (2a) decelerates.

2. The casting plunger system of claim 1, further characterized by one or more additional masses (ZK, ZK1, ZK2, ...) configured to be releasably attached to the system part to be moved and, in the attached state, forming components of the system part to be moved.

3. 3. The cast plunger system of claim 2, further comprising a plurality of additional masses, at least two of said additional masses having different masses.

4. 4. A casting plunger system according to claim 2 or claim 3, further characterized in that the stationary system part comprises an additional mass storage unit (6) for storing and providing one or more of the additional masses.

5. 5. The casting plunger system according to claim 2, further characterized by an additional mass handling unit (7) configured for automatically attaching and detaching the additional mass to and from the system part being moved.

6. moreover, A set of cast plungers (31, 32) having different masses, each of which is known in advance. a set of a plurality of cast plungers (31, 32, ...), each of which differs in mass by a known mass increment, and which are adapted for interchangeable use as cast plungers of the system components to be moved; and / or A set of cast plunger rods (41, 42) each having a different mass, the mass of which is known in advance. , . . . ), the masses of which differ by a known mass increment and which are adapted for interchangeable use as cast plunger rods of the system components to be moved; and / or A set of cast plunger joints (91, 92) each having a different mass, the mass of each joint being known in advance. , . . . ), whose masses differ by a known mass increment each, and which are configured for interchangeable use as the cast plunger joints (9) of the rod drive units of the system components to be moved. , . . . ), and / or A set of cast plunger drive pistons (101, 102) each having a different mass, the mass of each piston being known in advance. , . . . ), whose masses differ by a known mass increment each, and which are configured for interchangeable use as cast plunger drive pistons (101, 102) of the rod drive units of the system components to be moved.

6. The cast plunger system of claim 1, further characterized by:

7. The relatively movably arranged additional mass unit comprises an additional mass (ZM) arranged on the main system component to be moved and slidably movable between a start position and an end position, The casting plunger system of any one of claims 1 to 6, further characterized in that the start position is defined by an initial end stop (IA) on the main system part to be moved and / or the end position is defined by an impact end stop (AA) on the main system part to be moved.

8. the initial end stop (IA) is adjustable on the main system part to be moved, and / or A casting plunger system according to claim 7, characterized in that the impact end stop (AA) is adjustable on the main system part that is moved.

9. The casting plunger system according to claim 7 or claim 8, further characterized by a locking unit (11) for releasably locking the additional mass in the start position or in the end position or in a predefinable locking position between the start position and the end position.

10. A casting method for a die casting machine having a casting plunger system according to any one of claims 1 to 9, comprising the steps of: At least one casting parameter of each casting cycle is detected; and A casting method, in which the mass of the system part to be moved and / or the delay time of the additional mass unit arranged to be relatively movably are variably adjusted for one or more future casting cycles depending on at least one detected casting parameter.

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