Digital Die Casting Apparatus Mold Locking and Injection Control
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Solution Overview
Problem
Conventional die casting machines face issues with inaccurate mold locking, mechanical damage, heat management, unstable material feeding, labor-intensive installation, and temperature control, leading to inconsistent casting quality.
Innovation Solution
A digital full-automatic die casting apparatus featuring a mold locking mechanism with a fixed-point servo motor and hydraulic assembly for precise positioning, an eccentric wheel structure for stable injection, a cooling water passage system to manage heat, an automatic mold correction mechanism, and an automatic loading device for precise material control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If only oil hydraulic cylinder is used for mold locking, then the structure is simple, but the mold locking position accuracy is poor
Solution Approach 1:
The patent combines the oil hydraulic cylinder with a fixed-point servo motor and transmission structure to form an integrated mold locking device. The hydraulic cylinder provides locking force while the servo motor with transmission structure (including screw-nut mechanism) provides precise position control, merging two functional systems to achieve both simplicity and precision.
Solution Approach 2:
The patent replaces pure mechanical positioning with a servo motor-driven transmission system that uses electrical control for precise positioning. The fixed-point servo motor controls the transmission structure to achieve accurate mold locking position, substituting mechanical trial-and-error positioning with controlled mechanical transmission.
2Device complexity
If push-down mechanisms and injection plungers are rigidly connected, then the structure is simple, but mechanical damage occurs easily and injection completion cannot be guaranteed
Solution Approach 1:
The patent replaces rigid connection with a flexible connection system where the injection plunger is connected to the push-down mechanism through a flexible link. This allows the injection plunger to move independently to ensure complete mold cavity filling while preventing mechanical damage from rigid constraint.
Solution Approach 2:
The patent incorporates a position detection device to monitor the injection plunger position and provides feedback to the control system. This feedback mechanism ensures that the injection process continues until the mold cavity is completely filled, guaranteeing injection completion and improving operational reliability.
3Productivity
If injection device reciprocates for injection operation, then injection is completed, but large amount of heat is generated affecting driving mechanism
Solution Approach 1:
The patent introduces a cooling water passage system as an intermediary between the injection device and the driving mechanism. The cooling water passage acts as a thermal barrier, allowing heat dissipation from the injection device without directly transferring heat to the driving mechanism, thus protecting the driving mechanism from thermal damage.
4Device complexity
If simple piston structure is used in material chamber, then the structure is simple, but piston shifts left and right and sealing stability is low
Solution Approach 1:
The patent modifies the symmetric piston structure by adding an asymmetric guide structure with inclined planes. The guide structure has a specific geometric configuration that constrains the piston to move vertically while preventing lateral shifting. The asymmetric design provides stable sealing by guiding the piston along a precise path.
5Ease of manufacture
If manual installation and positioning is performed, then the device can be installed, but it is time-consuming and laborious causing inaccurate positioning
Solution Approach 1:
The patent incorporates pre-positioning features and alignment mechanisms that enable automatic installation and positioning of the injection device. The preliminary design of positioning components allows the device to be automatically aligned and secured during installation, eliminating the need for time-consuming manual positioning operations.
6Ease of operation
If manual feeding materials into furnace is performed, then materials can be added, but addition cannot be controlled causing temperature drop affecting product quality
Solution Approach 1:
The patent implements an automatic material feeding system with sensors that detect material levels and trigger automated feeding operations. The system serves itself by monitoring its own state (material level) and automatically adjusting the feeding process, eliminating manual control variability and ensuring precise temperature control through consistent material addition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves high precision, stability, and efficiency in mold locking, injection, and material handling, ensuring consistent casting quality and reducing labor and energy consumption.
Implementation Method 1
a hydraulic mold locking assembly connected to the mold locking fixed-point assembly; the hydraulic mold locking assembly acts on the nut
Implementation Method 2
a cooling water passage system to manage heat
Data Source
AI summary
A digital full-automatic die casting apparatus, including a longitudinal mounting plate, a mold arranged on a front surface of the longitudinal mounting plate, a mold locking device including a plurality of mold locking mechanisms surrounding a periphery of the mold, an injection device arranged on a back surface of the longitudinal mounting plate, and a PLC controller electrically connected to the mold locking device and the injection device respectively, The mold locking mechanism includes a mold locking fixed-point assembly arranged on the longitudinal mounting plate, and a hydraulic mold locking assembly connected to the mold locking fixed-point assembly; the mold locking fixed-point assembly includes a fixed-point servo motor arranged on the longitudinal mounting plate and electrically connected to the PLC controller, a fixed-point screw connected to the mold, a nut screwed to the fixed-point screw, and a transmission structure connected between the fixed-point servo motor and the nut.