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Chapter 4 Overview

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Moving platen s along the tie bars. Size and strength of the tie bars determines the size of the DCM ... Some DCM's replaced tie bars with a solid frame ... – PowerPoint PPT presentation

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Title: Chapter 4 Overview


1
Chapter 4 Overview
  • The DCM is very complex
  • Mechanical, electrical, hydraulic and safety
    systems all work together
  • Each system has many components
  • Additional equipment may be used

2
Chapter 4 Objectives
  • Using a quality photograph, correctly identify
    all structural components, electrical system
    components, hydraulic pump components, and safety
    devices
  • Identify the purpose of all structural
    components, electrical system components,
    hydraulic pump components, and safety devices

3
New Term
  • Solenoid
  • An electromagnet that shifts a metal core

4
DCMs Systems
  • Structural
  • Electrical
  • Hydraulic
  • Safety

5
Structural Components
  • Structural components framework
  • DCM Base
  • Support
  • Shape is generally a rectangular box
  • Usually extends under the entire DCM
  • Rear portion enclosed to form a steel tank used
    as a reservoir for the hydraulic fluid/oil

6
Structural Platens
  • 3 large plates that carry the DCM loads
  • Rest on the DCM base
  • Stationary at front of DCM
  • Holds stationary die half on die space side
  • Moving between stationary rear platen
  • Moving/ejector half of die is mounted to it
  • Rear at rear of DCM
  • Slides back and forth as the tie bars stretch

7
StructuralTie bars
  • 4 tie bars are long, round, solid beams
    mounted through four corners of platens
  • Hold the DCM together
  • Moving platen slides along the tie bars
  • Size and strength of the tie bars determines the
    size of the DCM
  • Some DCMs replaced tie bars with a solid frame
    made from a casting

8
Structural Toggle mechanism
  • Connects rear and moving platens
  • Acts as a lever and gains a mechanical advantage
    during die close and locking
  • It overcame the deficiencies of using a large
    cylinder

9
Electrical Components
  • Electrical energy powers and controls the DCM
  • The electric power is converted to hydraulic
    energy in order to do the actual work of the DCM

10
Electrical Motor and Control Panel
  • Electric motor(s) located at rear of DCM are
    directly coupled to the hydraulic pump
  • Electrical energy is converted into hydraulic
    energy
  • Pumps force oil into the hydraulic lines under
    pressure
  • Pose electric shock hazard

11
Electrical Solenoids
  • Shift the valves that control the volume and
    direction of hydraulic oil flow

12
Electrical Limit Switches
  • Limit switches are the sensors, the eyes and
    ears, of the electrical control system
  • Sense the position of doors, guards, cylinders
    and other moving components
  • Maintenance is essential to the safe operation
    of the DCM
  • Other types of switches and sensors, also

13
Hydraulic System
  • DCM is operated by a hydraulic system
  • A fluid, fire-resistant oil is used to power the
    cylinders that make the DCM move
  • Operates at high pressures and high flow rates
  • Hydraulic fluid is hot and can cause burns
  • Repair/clean leaks and spills quickly

14
Hydraulic Hydraulic pumps
  • DCM typically has two hydraulic pumps
  • One pump capable of providing oil at high
    pressures but in low volumes
  • A second pump capable of providing a high volume
    of oil at low pressures

15
Hydraulic Filters
  • Filter(s) are required to keep the hydraulic
    fluid clean
  • Located at the outlet of the pumps
  • Require routine maintenance

16
Hydraulic Valves
  • Used to control amount and direction of oil flow
  • Solenoid-operated valves direct the flow to the
    head or rod side of a cylinder or direct oil to
    shift a large valve
  • May be manually operated
  • Series of valves mounted on a manifold may
    control the DCMs speed control

17
Hydraulic Heat Exchanger
  • Operates similarly to a boiler
  • Hot hydraulic oil and cooling water run through
    the heat exchanger the water cools the oil
  • Leakage can be troublesome
  • Hydraulic oil could be contaminated by water
  • Cooling water could be contaminated by the
    hydraulic oil

18
HydraulicCylinders
  • Open and close the DCM
  • Inject the metal into the die
  • Operate the ejection system
  • Move slides on the die
  • Actuate a safety ratchet and open and close a
    safety door at the die parting line

19
HydraulicInjection Components
  • Inject the metal into the die
  • Hot chamber components include
  • Shot cylinder, plunger coupling, plunger, rings,
    gooseneck, bushing and nozzle

20
HydraulicInjection Components
  • Cold chamber components include
  • Shot cylinder, plunger rod and tip, coupling and
    the cold chamber

21
HydraulicAccumulator
  • A large steel tank
  • Partially filled with hydraulic oil
  • Above oil is high-pressure nitrogen gas
  • Used when large volume of oil required

22
Hydraulic Intensifier
  • Hydraulic device that increases hydraulic fluid
    pressure at end of injection stroke
  • This high pressure dramatically increases the
    metal pressure to
  • Squeeze additional metal into the die cavity as
    the metal shrinks
  • Further compress trapped gases

23
Safety Components
  • Die casting workplace has many hazards associated
    with it
  • DCM operates with high pressures, high forces,
    and high voltages using liquid metal at high
    temperatures
  • Need safety components and devices help ensure
    everyones safety

24
Safety cont.
  • Die space area is protected by safety doors or
    gates
  • Prevent access to this area when the DCM closes
  • Guards at the toggle mechanism prevent access to
    mechanism when operating
  • Safety ratchet prevents the DCM closing
  • DCM will only close if safety conditions have
    been met and ratchet dog is withdrawn

25
Summary
  • Structural system form the basis of the machine,
    providing support
  • Electrical system provide power to the machine
    and control it
  • Hydraulic system use a fluid, fire-resistant oil
    to power the cylinders that make DCM move
  • Safety components help prevent injuries and
    accidents, when used appropriately and coupled
    with safety-conscious actions
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