Die-Casting Piston Lubrication With Precise Oil Metering
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Solution Overview
Problem
Existing die-casting machines require excessive lubricant for wear reduction, leading to inefficiencies and environmental concerns, with previous solutions only partially reducing lubricant consumption.
Innovation Solution
A die-casting device with a lubricant supply system featuring a time-displacement-controlled drive interacting with a lubricant cylinder, allowing precise control of lubricant quantity through valve control and servo-electric drive, enabling minimal lubricant usage with variable distribution based on friction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large quantity of lubricant is used for lubrication of the die-casting piston and filling chamber, then wear reduction is achieved, but lubricant consumption is excessive and economically inefficient
Solution Approach 1:
The lubricant is pre-injected into the piston rod before the die-casting piston is inserted into the filling chamber. This preliminary action ensures that the lubricant is already in position to reduce wear during the subsequent casting process, eliminating the need for continuous lubricant supply and reducing overall consumption.
Solution Approach 2:
The lubrication system is integrated within the piston rod structure itself. The piston rod contains internal channels and cavities that hold and distribute the lubricant, nesting the lubrication function within the existing mechanical component rather than adding separate external lubrication systems.
2Loss of substance
If precise metering of lubricant quantity is implemented, then lubricant consumption is reduced, but system complexity increases due to additional control mechanisms
Solution Approach 1:
The system uses the existing motion of the die-casting piston to automatically trigger and control the lubricant injection. The piston rod's movement into the filling chamber directly actuates the lubricant release, making the system self-regulating without requiring external sensors, controllers, or complex metering mechanisms.
Solution Approach 2:
The lubrication function is merged with the piston rod's existing mechanical structure and motion cycle. The lubricant delivery is combined with the natural reciprocating motion of the die-casting piston, eliminating the need for separate drive systems and reducing overall system complexity.
3Reliability
If variable lubrication distribution is implemented based on friction conditions, then lubrication efficiency is improved, but control system complexity increases
Solution Approach 1:
The piston rod is designed with different internal sections that distribute lubricant to specific locations along the filling chamber wall. Different segments of the piston rod can deliver lubricant at different positions, providing localized lubrication where friction conditions vary along the stroke, without requiring complex real-time control.
Solution Approach 2:
The lubricant delivery occurs in periodic pulses synchronized with the die-casting piston's motion cycle. Lubricant is injected at specific phases of the piston stroke when friction conditions require it, using the periodic nature of the casting cycle itself rather than continuous monitoring and control.
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
Achieves precise and efficient lubrication with significantly reduced lubricant consumption, optimizing machine operation and extending component service life while maintaining high casting quality.
Implementation Method 1
a lubricating fluid pump is provided, which pumps the lubricating fluid from a reservoir to the lubrication device
Implementation Method 2
The lubricant supply system has a time-displacement controlled drive that interacts with a lubricant cylinder, the amount of lubricant being determined by the stroke of the lubricant cylinder
Data Source
Figure 1
AI summary
The invention relates to a die-casting device with a filling chamber and a die-casting piston with a piston rod, which are arranged displaceably in the filling chamber, the piston rod having a lubricating device with at least one lubricant channel and at least one lubricating opening, via which lubricant can flow into a space between the outer circumference of the die-casting piston and an inner circumference the filling chamber located area can be introduced. Furthermore, the die-casting device includes a lubricant supply system, which conveys lubricating fluid from a reservoir to the lubricating device. The lubricant supply system has a time-displacement-controlled drive that interacts with a lubricant cylinder, with the amount of lubricant being determined by the stroke of the lubricant cylinder. In the lubricant cylinder, a predefined quantity of oil can be sucked in from a reservoir and introduced into the piston rod of the die-casting piston via a valve control. Furthermore, the invention relates to a lubricant supply system and a lubrication method.