How innovative valve technology can improve cooling of die casting processes
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1 How innovative valve technology can improve cooling of die casting processes White Paper May 2011
2 How innovative valve technology can improve cooling of die casting processes Dr. Egon Huefner, Segment Manager Cooling Systems, Bürkert Fluid Control Systems Pressure from the automotive industry necessitates increasingly stringent standards of quality for die-cast parts and therefore for the temperature control of die-casting tools. All processes must be exactly reproducible and traceable. In addition, the cooling system must allow for modular expansion, with the smallest possible dimensions. Thanks to modern modular valve and sensor technology, such demanding cooling systems can be tailored exactly to the requirements of the respective application. Modern automated die-casting processes enable the large-series production of lightweight, thin-walled die-cast parts with extremely small tolerances, a smooth surface and well-defined contours. Computer-controlled die-casting machines with automatic temperature control of the die-casting tools ensure reproducible, consistently high quality of all parts, even in the case of large production quantities. Temperature control in the mould is decisive for stress-relieved cooling of the workpiece. Temperature channels just below the surface of the die cavity provide for good heat dissipation and relatively even temperatures in the die-casting mould. The shape of the workpiece and the heat transfer fluid determine the design of the cooling channels and the maximum possible mould tempera- 2
3 ture. If fast dissipation of large quantities of heat is necessary, the use of water or a water/air mixture as a coolant is the preferred method (Fig. 1). Fig.1: The principle of air/water cooling of die-casting tools The number, design and arrangement of the cooling channels in a die-casting mould are important for successful temperature regulation. Specifically, many small channels enable more precise temperature control than a few large holes. Modern die-casting systems generally provide for 5 to 30 cooling channels for each mould. But there are also designs with up to 100 cooling channels. However, the temperature of the coolant and the flow rate are decisive for absolutely precise and reliable temperature control. State-of-the-art sensors detect flow changes within 100 to 300 milliseconds and optimized control valves adjust the flow rate immediately within 0.3 to 1 seconds to guarantee constant and reproducible cooling. New valve and sensor technology Several independent and parallel cooling circuits ensure more precise control of the cooling process, which improves the quality of the die-cast parts. The new development of proportional solenoid valves enables the implementation of multi-loop parallel-working flow rate regulation circuits. The advantage of the solenoid valves lies in the frictionless bearing of the magnetic core ensured by special form springs that avoid stick-slip effects. This is reflected in an excellent performance record comprising paramount response sensitivity (0.1 per cent of the final value), minimal reversal errors and excellent regulation performance. The measuring range of these new proportional solenoid valves is 1:100, which makes it possible to adjust to even the slightest fluctuation in the flow rate by very precise corrective movements of the valves. In combination with the new ultrasonic flow rate sensor, which has a measuring range of 1:200 and starts measuring at 0.06 l/min (3.6 l/h), it is possible to dose very 3
4 small and precise flow rates to air flows ( Fig. 2). Fig. 2: Flow control system with solenoid control valve Type 2835, ultrasonic Flow sensor Type 8081 and econtrol 8611 (flow rate range l/min) Modular valve bodies enable more compact systems Innovative, modular valve bodies eliminate the need for conventional pipeline connections between the single valves (Fig. 3). The fluid connections are achieved by direct joining of the valve bodies, which enables the design of extremely compact, space-saving and robust valve systems for the cooling of die-casting tools. Since the inlet and outlet planes are separate in the new valve bodies, redirection of the fluid flow is reduced in comparison with conventional valves. The new valves therefore also optimize the kv value. Due to the modular design it is even possible to produce small batches cost-effectively. The applications range from single valve solutions to complete control cabinet systems. Fig. 3: Modular valve block for cooling of die-casting tools 4
5 Optimally compatible control technology Special controllers are necessary for adjusting the quantity of coolant or air/ water mixture, for example to achieve an exact ratio of air to water. Another of Bürkert s strengths: The company offers all actuators, sensors and controllers necessary for decentral control of the temperature in the die-casting mould, which facilitates the control of specific machines. Decentral temperature control of the mould can also be easily retrofitted to easily and quickly bring existing systems into conformity with the state of the art. Bürkert s product portfolio includes a wide selection of valves, sensors and controllers for gases and fluids. The usual integrated flow system consists of a flow sensor (paddle wheel or ultrasonic principle), a proportional valve (electric or pneumatic) and a flow rate controller that can be combined with various valve types. The controller plays a decisive role within the system as it has to be able to process different sensor signals such as temperature, pressure or flow rate. And it must be capable of addressing pneumatic and electric control systems. The new universal controller econtrol 8611, specially developed by Bürkert for cooling systems, fulfils all of these requirements and is also available as a panel version with a 1/16 DIN cut-out for installation in an existing control cabinet (Fig. 4). Fig.4: Control cabinet solution with innovative Bürkert valve technology 5
6 Contact Can we help you to improve your process efficiency and the quality of your work pieces by means of absolutely precise and reliable temperature control of die-casting moulds? Or do you have further questions? Just contact Dr. Egon Hüfner Segment Management Cooling Systems Bürkert Fluid Control Systems Bürkert Werke GmbH Christian-Bürkert-Straße Ingelfingen Tel: Website: 6
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