1. DESCRIPTION Two-Platen Cold Chamber Aluminium High Pressure Die Casting Machine Series REVOLUTION Model OL 1800 R

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1 1. DESCRIPTION Two-Platen Cold Chamber Aluminium High Pressure Die Casting Machine Series REVOLUTION Model OL 1800 R 2. TECHNICAL SPECIFICATIONSDIE CASTING MACHINE TECHNICAL DATERIES Brand: Idra Model: OL 1800 R Year Manufactured: 2013 Clamping force: KN (1890 metric tons / 2080 US tons) Injection force (back pressure 0/20): 1.193/1.080 KN Central ejection force: 630 KN Max. die height: 1450 mm Min. die height: 750 mm Platen dimensions: 1,960 x 1,960 mm Distance between tie bars: 1,225 x 1,225 mm Tie bar diameter: 275 mm Moving platen stroke: 1,300 mm Injection stroke: 900 mm Central ejection stroke: 255 mm Line pressure: 160 Bar Max. shot weight (Al alloy): 12,1 Kg. Max. projected area (400 bar): cm2 Pump motor power: 2 x 37 kw Machine weight: 80 Metric Tonnes Machine overall dimensions (L x W x H): 9,800 x 4,400 x 4,600 mm 3. DETAILS 3.a Horizontal cold chamber basic machine configuration and standard equipment Basic machine includes: Electric Installation and Control System: o ABB control cabinet frame o PLC Siemens series S7 o Idra Inject Computer II Supervision System for parameters setting, diagnostics and control of peripherals interface o Graphic display of curves, control of quality and production o Roof-mounted air conditioner in control cabinet o Hour counter and electronic cycle counter integrated in the Supervision System o Standard cable length from control cabinet to machine pumps: 7 meters o Free standing operator s panel standard cable length 4 meters o Transducers on closing, central ejection and injection stroke o Electric circuit with decentralized Profibus logics with reduction of cable number either for control cabinet connection and on the machine Electric Interfaces for: o Automatic injection plunger lubrication o Injection pressure reduction o Automatic metal ladle unit, type CLE or CRE in Profibus o Automatic die lubricator, type LS in Profibus o Robot type ABB for casting take-off in Profibus o IDRA standard core-pull programs (see technical description) Hydraulic installation and Injection Unit: o Hydraulic control with proportional valves and final brake o Final brake on injection movement with Parker TDP valve o Intensifier for final pressure intensification, separated 1

2 o Progressive injection o Fluid level control in tank o Fluid heating with pump in low pressure o Plate heat exchanger with circulating pump o Exclusion valves on hydraulic system (Injection, Clamping, Central Ejection) to easy fault tracing Central ejection and core-pull unit o Hydraulic central ejection by means of two cylinders driving a bumper plate o Settable delay on central ejection control o Interface for mechanical central ejection o Core-pull control (Group 1) on moving platen Clamping Unit: o Automatic point-to point oil lubrication o Adjustable sliding shoes on moving platen o Tie bar tonnage monitoring by means of a pressure transducer o Clamping system with 4 independent hydraulic cylinders on tie bar back side Safety: o Die safety (final close in very low pressure) o Die filling check (injection piston stop at 2nd phase start point) o Electrical safety guard on operator s side (fixed to the floor) o Electrical safety guard on operator s opposite side (fixed to the floor) o Accident coverage for all moving parts o Protection guards (manually operated) on both injection sides o Electro-hydraulic safety on closing/opening Documentation: o No. 1 set of machine operating and maintaining manuals (paper copy) o No. 1 copy of machine operating and maintenance manuals on CD-ROM (available languages : Italian, English, German, French, Spanish. Other languages on request) o EC Certificate type A for the machine only according to the current rule 2006/42/EC 3.b Auxiliary and/or requested machine equipment The machine is equipped with the following accessories: 1. Electrical Installation and Control System o S.P.C Statistical data analysis with management of production Database o Pre-arrangement for Connection to Network and Remote Control o 4 meters additional cable length from cabinet to machine (total 11 meters) o 4 colour lamp on control cabinet o Inject Computer II 2. Electric Interfaces: o Electric interface for Vacuum System o Electric interface for Dosing Furnace o Electric interface for die heating/cooling units o Electric interface for Jet Cooling o Interface for spray equipment with support on fixed platen 3. Hydraulic Installation and Injection Unit o Automatic injection plunger lubrication o I.C.S. II (IDRA Control System II) for closed loop control of the injection speed up to 10 set points o Protection carter for injection movement 4. Central Ejection and Core-pull Unit 2

3 o No. 5 Additional core-pull on moving platen (total 6) o No. 2 core-pulls on fixed platen o Pilot controlled check valves for corepulls installed on moving and fixed platen for each core o Free programming of corepulls and squeeze pins o 125 lt. accumulator for corepulls on moving platen 5. Clamping Unit: o Automatic removal of two upper tie-bars o Individual Self Compensating Automatic Tie Bar Adjustment 6. Quick die change devices: o Automatic die clamping according to specifications o Automatic central ejection clamping, rod type (third plate) 7. Miscellaneous: o Manifold with 12-way flow meter type SELLA RT with cooling fluid flow and temperature digital measurement as per specifications. Complete with management page in the Inject Computer II Supervisor to enable the use also flows and temperatures of the die cooling circuits as process parameters. Values are recorded in the production Database together with all other process parameters. O Die cooling water manifold system complete with: O 6 circuits on moving platen O 4 circuits on fixed platen o 2 circuit for plunger o Complete pipework with distribution manifolds, flow control, solenoid valves and controls o Machine labels and instruction manuals 4.1 TWO-PLATEN COLD CHAMBER ALUMINIUM 4. DISCRIPTION DIE CASTING MACHINE SERIES REVOLUTION Cold chamber aluminium die casting machines series Revolution manufactured by Idra represent a further technological development given to foundries to successfully face competition challenge. In opposition to traditional toggle machines, the clamping unit individually occurs on the 4 tie bars by means of hydraulic actuators with reduced fluid volume, in order to assure the same sturdiness than the toggle machine clamping unit MACHINE BASE Base of machine to have drilled clearance holes for levelling pads DIE INTERFACE SYSTEM Central ejection unit consisting of an oversized plate and operated by two hydraulic cylinders and holes for manual drawbar connection. Flow control provided and low force ejection return. Mechanical interface on the of top of stationary platen for mounting customer equipment (mounting plate for specific reciprocator can be purchased separately) Three standard shot positions according to platen drawing. Other positions are available upon special request. Shot insert is provided which allows for various future shot positions CLAMPING UNIT Automatic lubrication system of movable parts. Lube pump, reservoir, low lube fault detection and controls included.reservoir mounted right hand rear of machine. Movable Platen uses an adjustable support riding on hardened steel rails using nonmetallic 3

4 wear pads and way wipers. Special bronze lubricated tie bar bushings are provided on movable and bumper plate complete with scrapers to eliminate tie bar scoring and increase bushing life. Die closing is accomplished with dual opposing die close cylinders. Die close cylinder oil is supplied using efficient pumps having adequate flow rate for die travel. Machine tonnage is developed with hydraulic Tie Bar Nuts. Clamping unit cylinder ID hard chrome plated. Plunger and plunger rods with special long life seals. Acceleration and deceleration control for die open and close is provided. A closing transducer continuously monitors the exact position of the moving platen Tie bar material is 39NiCrMo3 steel, hard chrome plated. Hardened specially surface treated compression rings are supplied in stationary platen. This provides corrosion resistant surface on ID and OD, and durable load distribution of tie bar compression. All moving parts are lubricated. Die Height is automatically accomplished using the die closing cylinders. The closing system automatically closes under low force. This low force system protects the die if an obstruction is met during the closing of the machine (die safety). Die lock system operated by four corner hydraulic lock-up mechanism using specially designed hydraulic cylinders accomplish consistent lock-up of the die. Tonnage is set via machine supervision system and is accurately controlled with the machine PLC. Equal pressure and therefore tonnage is supplied to all 4 tie bars INJECTION SYSTEM The injection unit is in integrated and modular hydraulic steel blocks which avoid use of external pipes thus reducing the risk of oil leaks. Lifting for injection position adjustable by means of a hydraulic cylinder. Hard chromed injection cylinder with with a one-piece injection piston and glide rings and pressure seals. Speed adjustment of the injection phases is by means of proportional valve which controls the flow on the cylinder discharge to enable final braking. The 3-phase injection system has a pressure intensifier with separate control circuit. Intensification plunger is monobloc, positioned in line with the injection cylinder, is connected to a rod that displays the movement. Independent flow control of the 3 injection phases with proportional valves for fast reaction times and consistent repeatability. The injection cylinder diameter is sized to guarantee an adequate injection force even with castings of reduced thickness and dry shot speeds higher than 7.5 m/s. Third phase intensification is by means of a separate intensification cylinder with control of the final pressure value with back pressure control by the Idra Bicostant system assuring a reliable constant final value and reducing pressure peaks due to intensification high speeds. Intensification plunger movement is displayed on an external rod. The Patented Biconstant system controls the final pressure value (intensification). It consists of an oil-nitrogen accumulator, which adjusts the intensification cylinder backpressure by absorbing the pressure peaks associated with intensification high speeds. The system guarantees repeatability of the final pressure value and dry intensification times lower than 15 milliseconds. With the ICS II system, IDRA Control System II, (supplied as an option), adjustment of the injection parameters is in real time. This system gives the following advantages: o Higher process repeatability (better CP and CPK) o Reduced flash with final shot brake o Pressure peaks are eliminated o Setting the curves for die cavity filling (up to 10 speeds) HYDRAULIC UNIT 4

5 The hydraulic unit of the OL R range machines is made exclusively with components from international high qualified vendors. Maximum hydraulic line pressure 160 bar. The unit has a large capacity tank incorporated in the machine base with an electric levelcontrol and filtering system. Hydraulic proportional valves situated on manifold with cartridge valves control all movement flows and pressures. High pressure flexible hoses are used to minimize rigid pipes. The unit is equipped with exclusion valves to simplify hydraulic fault finding. The hydraulic circuit with proportional valves enables the following parameters to be set: o Flows Pressures o Die mounting Die mounting o Moving platen approaching by cylinders Low pressure o Die safety High pressure o Final closing flow Slow closing o Slow opening Closing final pressure o Fast opening Slow opening o Opening brake Opening brake o Central ejection forward-back Central ejection forward o Fast-slow die height adjustment Die height adjustment o Core pulls IN-OUT Biconstant charge (intensified pressure) o 1st phase with pump o 1st phase with accumulator (progressive) o 2nd injection phase (fast shot) o 3rd injection phase (intensification) o Injection final brake o Biscuit ejection o Injection plunger return o Min.-max. flow ELECTRIC UNIT The electric system on the machine is wired with armoured metal sheaths and fireproof cables. The electric control is positioned in a separate control panel. The electric unit conforms to the CEI, VDE, IEC safety standards. Electronic control panel with Siemens S7 PLC. Idra Supervision System Inject Computer II for parameters setting, complete with integrated diagnostic, peripheral equipment interface control and air conditioner. Visualized pages are about 90 depending on equipment configuration. Operator interface with 15 TFT industrial display (resolution 1024 x 768 dpi) and trackball keyboard with the following functions: o Interactive synoptic with Help function o Simplified setting of parameters and operation cycles o iagnostics and alarms with help functions for faults finding, storage of data and statistical analysis with graphic visualization Controlled and visualized alarms are: o 600 for only diecasting machine o 300 for ABB Robot o 80 for metal ladle CLE o 160 for die lubricator LS o 100 for trimming press 5

6 o 50 for die thermoregulating units o Additional 80 alarms which can be personalized for other eventual devices belonging to the equipment such as vacuum system, marking devices, etc. Peripherals such as : extracting Robot, Die Lubricators, Trimming Presses and Die Thermoregulating Units connected in Profibus are completely integrated in the supervision system and alarms are available in the same ways as machine alarms, so that trouble shooting and production restart are simplified. Machine programme is recalled from die data file and programmes for peripheral operation are automatically activated. Graphic display of curves, control of quality and production Visualization of injection curves for: o Speed o Stroke o Pressure o Memorization of the master curve with possibility of overlapping for comparison with each injection curve. Numerical control of 14 process parameters with the possibility to set tolerance values and to use the parameters output signal for casting selection Production control with possibility to create production database files which can be transferred to the company management system. Voltage control for 24V inputs and outputs with I/O cards on machine (Profibus). All machine movements, core pulls and central ejection are according to the selected program and fully protected by interlocks LUBRICATION UNIT Automatic central lubrication, oil type point to point with pump-tank group, electric level control and pressure switch to control the lubrication cycle. The operator can adjust intervals and duration PRE-ARRANGMENTS The pressure die casting machine is equipped with the following electric and hydraulicmechanic pre-arrangements: o Automatic die lubricator o Automatic injection plunger lubrication o Automatic metal ladle o Core pull program o Injection pressure reduction o Closing mechanical safety COMMERCIAL COMPONENTS USED The system is made with the following main components: o PLC Series S 7 SIEMENS o Electric motors ABB - SIEMENS o Motor reducers for electric doors BONFIGLIOLI o Hydraulic pumps DENISON o Plate heat exchanger ALFA-LAVAL o Hydraulic filters PARKER o O-Ring seals PARKER (NBR) o Piston seals BUSAK-SHAMBAN o Solenoid valves PARKER o Proportional valves PARKER o Piston type accumulators HTP o Nitrogen bottles HTP 6

7 o Nitrogen safety valve PARKER o Oil lubrication DROPSA o Injection plunger lubrication ACHESON o Limit switches SIEMENS o Position sensors SIKO (magnetic) o Squeeze pin accumulators PARKER o Welded flanges according to SAE J p.s.i. o Flexible pipes according to DIN SP pren 856/4 SP; DIN SH pren 856/4SH; DIN SN pren 853/2SN CORE PULL STANDARD PROGRAMS The standard machine conforms to the following rules or regulations: o UNI EN Machinery Safety (basic methodology) o UNI EN Machinery Safety (technical principles) o UNI EN Machines electrical equipment (for machine with electrical control) o 2004/108/EC Electromagnetic Compatibility o According to rules 2006/42/EC o According to harmonized standards EN 869 Safety requirement for high pressure metal die casting units. o CE Certificate type A for the machine only according to the current rule 2006/42/EC The main safety protection and prevention devices installed on the machine are: o Automatic safety door, electrically driven, on machine operator's side, o Electrically operated safety bar with dampers o Manual door on operator s opposite side with electric safety control o Protections for all moving parts on both the closing and injection units o Two hand control for machine movements o Electro-hydraulic interlock for machine closing o Accumulators and safety valves with 97/23/EC PED (Pressure Equipment Directive) certificates o Electro-mechanical interlocks for all machine movements o Die mounting system in low pressure STANDARD SUPPLY Standard equipment includes: o No. 1 paper copy and No. 1 electronic copy of the machine Use and Maintenance Manual. o No. 1 set of special spanners o No. 1 set of seals o Standard cable length between control panel and the derivation box positioned on the rear side of the machine is 7mt. PROGRAM 1 PROGRAM 2 (without core pulls) (with core pull group 1 on movable plate) Sequence of cycle operation: o Door closing - door closing o Machine closing - core pull 1 IN o Injection - machine closing o Machine opening - injection o Adjustable door opening - machine opening o Ejection - adjustable door opening o Ejection return - core pull 1 OUT o Plunger return - ejection o Ejection return o Plunger return 7

8 PROGRAM 3 PROGRAM 4 (with core pull group 3 on fixed plate) (with core pull group 1 on movable plate) (with core pull group 3 on fixed plate) Sequence of cycle operation: o Door closing - door closing o Machine closing - core pull 1 IN o Core pull 3 IN - machine closing o Injection - core pull 3 IN o Core pull 3 OUT - injection o Machine open - core pull 3 OUT o Adjustable door opening - machine opening o Ejection - adjustable door opening o Ejection return - core pull 1 OUT o Plunger return - ejection o Ejection return o Plunger return PROGRAM 5 PROGRAM 6 (with core pull group 1 on movable plate) (with core pull group 1 on movable plate) (with core pull group 2 on movable plate) (with core pull group 2 on movable plate) (with core pull group 3 on fixed plate) Sequence of cycle operation: o Core pull 1 IN - core pull 1 IN o Core pull 2 IN - core pull 2 IN o Machine closing - machine closing o Injection - core pull 3 IN o Machine opening - injection o Adjustable door opening - core pull 3 OUT o Core pull 2 OUT - machine opening o Core pull 1 OUT - adjustable door opening o Ejection - core pull 2 OUT o Ejection return - core pull 1 OUT o Plunger return - ejection o Ejection return o Plunger return SAFETY DEVICE 8

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