Carat. The solution with highest value creation for sophisticated parts. Innovations for a better world.

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1 The solution with highest value creation for sophisticated parts. Innovations for a better world.

2 Reliable solution for higher casting performance. The integrated die casting solution for components with highest quality requirements. Carat is the two-platen die casting solution with a locking force from 10,500 to 44,000 kn. The system was designed specifically for manufacturing large and complex parts such as structural components, which need to meet the highest quality requirements. Thanks to the flexibly-designed Carat technology, the die casting process can be adjusted precisely for the components to be manufactured and to their properties Significantly improved energy efficiency. Reduction of energy consumption by over 20% due to optional control technology 2

3 1 Higher efficiency through two-platen technology. 2 Bühler technology for the best casting results. Stable production processes due to compact design and high rigidity Improved locking force distribution for reduced flash Use of larger sizes on the same floor space Using unique Bühler SC (shot control) systems, every die casting process is controlled in real time Reproducible casting results A process that is controlled, stable, and preserves the die 3 30% additional shot capacity for reliable production. 3 Powerful injection unit High dynamics for improved die filling Power reserves to compensate for process fluctuations and for a stable production 2 4 Intuitive DataView cell control. 5 Automation solution for high availability. Integration possibility for all peripheral devices High productivity due to synchronized communication of the cell participants Stable production process for maximum availability Intuitive and user-friendly control system for 25% shorter programming time Integrated process and system diagnostics Interactive real-time control of the die casting cell Linked with all cell participants and higher-level systems 3

4 Reliability, power and quality. Keep your production on the safe side with Carat. Higher efficiency through two-platen technology. The two-platen solution allows construction of significantly shorter machines. This allows systems with a higher specific casting output to be used in the same available space. The compact design with a high rigidity reduces flash and increases productivity thanks to more stable production processes. The service life of the platens is increased thanks to corrosion protection that is applied as standard. Intuitive DataView cell control. The complete die casting cell can be centrally and easily controlled using DataView. The innovative user interface is available in a number of languages. It provides support with practical assistance systems for targeted diagnostics and analyses. The control unit provides comprehensive support for daily operation and allows real-time control over the entire cell. The intuitive operating concept combines a multi-touchscreen with a clear, graphical user interface. This allows the employees to familiarize themselves with the system more easily and shortens the programming time by up to 25%. In addition, the DataView console distinguishes itself through its ergonomic design. 25% shorter programming time 4

5 Bühler SC casting technology with up to 30 % higher performance. Bühler has developed the unique SC (shot control) die casting technique with real-time closed loop control for maximum quality and efficiency. A generously designed hydraulic system provides sufficient power reserves to compensate for process fluctuations, which enables stable production. The high dynamics support optimal part filling. The die casting process is continuously monitored using SC technology and is controlled in real time. The system automatically reacts to deviations and corrects them immediately. This allows a process that has a high level of reproducibility and casting that particularly preserves the die. In addition, automated algorithms assist with programming optimal casting profiles, which results in shorter cycle times and a higher part quality. Maximum process flexibility. Structural parts, engine blocks and conventional parts, in aluminum or magnesium: No component and no process are exactly the same. Therefore, the Carat solution is modularly constructed and, with three performance levels for the injection unit and numerous additional options, can be configured precisely for specific applications. This means that each and every foundry receives a complete solution that is tailored to its specific needs. It provides the highest level of flexibility with regard to processes and technology. Hardware and software can be upgraded at any time, which ensures maximum protection of your investment. 30% higher performance 5

6 Automation solution for high availability. The die casting cell as an integrated production solution. High availability of the cell requires system components that are optimally tailored to one another. With the DataView control unit, all cell participants are aligned, programmed and controlled centrally. This allows the cell to be easily operated and monitored. The DataView control system doesn t just provide comprehensive analysis and diagnostic options; it also saves all relevant parameters and data centrally. Production and process data, as well as system configurations, are available at all times. The seamless exchange of information between all components also ensures that the Bühler cell is already equipped for use in a smart factory. 6

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8 Optimally synchronized cell. Seamlessly integrated peripheral devices for maximum availability. SmartVac Vacuum system with higher process transparency. The SmartVac vacuum system is integrated seamlessly into the die casting system. It is controlled centrally with the Data- View control unit. All relevant vacuum parameters are measured, monitored and assigned to the process directly for comprehensive process transparency and optimum quality of the components. SmartVac allows the use of many commercially available vacuum valves. Up to four suction points on the die and one on the shot sleeve can be controlled and monitored independently of one another simultaneously. The vacuum level and the suction level can be adjusted individually and targeted to the component and to the appropriate process. In addition, cyclical tests allow quick evaluation of the current filter condition, which allows for proactive maintenance. Achieves the ideal vacuum level quickly Centrally operated Increased process transparency BuhlMark Permanent marking for complete traceability. BuhlMark is a marking device that can be used flexibly and allows alphanumeric characters and codes to be applied in three different stamping types. The quick and permanent marking ensures unique and constant traceability. The device is specially optimized for use in the harsh conditions found in foundries. It has a completely protected stamping unit, and is therefore extremely low maintenance. Marking codes can be programmed directly on the cell control unit, and are a part of the die program. This means that all data is centrally available and enables error-free and quick change of dies. Complete traceability of parts Efficient and low-cost maintenance High flexibility 8

9 BuhlRob Reliable and fast extraction of parts. BuhlRob is a robot specifically designed for part removal in foundries. The system is based on the proven ABB or Kuka technologies. BuhlRob distinguishes itself through its compact design, its high range and a high working load. Compensation movements prevent collisions and thus also production interruptions during removal. In this way, BuhlRob contributes to a higher availability of the cell. Additionally, the device is integrated into the die casting system control unit and allows graphical visualization of the robot s functions. This allows all data to be clearly available and simplifies handling for the user. User-friendly Specially designed for foundries Fast extraction BuhlSpray efficient spraying. BuhlSpray is a two axis spraying device, and is offered in three expansion stages. With tools for up to eight spraying and blowing cycles, the device is also suitable for intricate cavities. The robust design and the simple structure contribute to a high level of availability for the die casting cell. The cycle time is minimized and productivity is increased thanks to the high dynamics of the device. BuhlSpray can be integrated seamlessly into the die casting system s control unit, which provides for simpler handling and quicker changing of dies. Easy and quick change of dies Rapid movements Centrally operated BuhlLadle Precise and consistent dosing. BuhlLadle is a ladling device for precise and consistent dosing of liquid aluminum. The device is distinguished by its robust design and its simple handling, and is entirely integrated into the control unit of the die casting system. The speeds and ladle angle can be programmed at will thanks to the servo technology. The extraor dinary positioning accuracy increases the dosing consistency and reduces the cycle times. Short cycle time High dosing consistency Simple handling 9

10 SmartVac. Technical data. 400/ / / / / / /400 Volumetric capacity of the vacuum tank l Vacuum pump (Busch) m³/h *160 2*200 Installed power kw Die evacuation unit Control system DataView DataView DataView DataView DataView DataView DataView Interface to DCM B B B B B B B Monitored die evacuation channels max. 4 max. 4 max. 4 max. 4 max. 4 max. 4 max. 4 Controlling / monitoring of chill events B B B B B B B Controlling / monitoring of hydraulic die valves B B B B B B B Controlling / monitoring of electric die valves B B B B B B B Profile monitoring per evacuation channel B B B B B B B Monitoring of contamination per evacuation channel B B B B B B B Alarm handling B B B B B B B Archiving of production data B B B B B B B Optimizing of 1 st phase on the DCM B B B B B B B Piping between vacuum generator and evacuation units on the DCM B B B B B B B Options Controlling / monitoring of mechanic die valves o o o o o o o Shot sleeve evacuation unit o o o o o o o Die evacuation unit 2 o o o o o o o Die evacuation unit 3 o o o o o o o Die evacuation unit 4 o o o o o o o Ejector box evacuation unit o o o o o o o Larger vacuum pump o o o o o o o Miscellaneous Die valves Suitable for Carat B Basic; o optional; not available Subject to change without notice. 10

11 BuhlMark. Technical data. Marking times for scribing and dot embossing (approximate)* Font set A: DIN 1451 or OCR-A scribing Font set B: HS (fast writing = slightly angular characters) scribing Font set C: 7 5 (dot matrix) dot embossing only The following marking cycle times were achieved with a marking unit 315 with marking controller EG-Box (ZAM5) with the marking heads DD20 L and R32 K. Font height in mm SH 1.8 SH 2 SH 2.5 SH 3 SH 4 SH 5 SH 6 SH 7 Figure set A B C A B C A B C A B C A B C A B C A B C A B C 2 figures figures figures figures single-spaced figures single-spaced figures single-spaced Max. figures per second Marking time for data matrix code ECC 200 (approximate)** Embossing: bidirectional = forward and backward embossing Code size in mm Embossing mode Bi Bi Bi Bi Bi Bi dots dots dots dots dots dots dots * All descriptions are purely marking times in-feed movements of the marking unit or marking heads as well as intermediate movements and movements towards the marking position or return to Home Position are not included. The marking times are reference values. Binding time specifications are only made by marking trial with an original workpiece. The marking speed can have a significant impact on the marking. The quality of the marking depends also on the built-in situation, rigidity of the marking unit parts (please notice our installation instructions), marking position, workpiece geometry and surface of the workpiece. ** All times stated are pure marking times, exclusive of feed travel of the marking unit or marking head or of detour travel and lengthy travel to the marking point. Subject to change without notice. 11

12 BuhlRob. Technical data. Model 4600F / Model 6700F / Number of axes 6 Number of axes 6 Handling weight (gripper and load) kg 40 Handling weight (gripper and load) kg 205 Maximum reach mm 2552 Maximum reach mm 2794 Programming RAPID Programming RAPID Connected power kva 7.8 Connected power kva 13 Interference contour robot (no gripper and load) (radius) mm 400 Interference contour robot (no gripper and load) (radius) mm 650 Robot weight kg 440 Robot weight kg 1260 Dimensions of control cabinet (LWH) mm (1370) Dimensions of control cabinet (LWH) mm (1370) Suitable for Carat 105 Suitable for Carat * Suitable for Carat under certain conditions Suitable for Carat under certain conditions Model 6700F / Model 7600F / Number of axes 6 Number of axes 6 Handling weight (gripper and load) kg 150 Handling weight (gripper and load) kg 150 Maximum reach mm 3200 Maximum reach mm 3500 Programming RAPID Programming RAPID Connected power kva 13 Connected power kva 13 Interference contour robot (no gripper and load) (radius) mm 650 Interference contour robot (no gripper and load) (radius) mm 700 Robot weight kg 1270 Robot weight kg 2530 Dimensions of control cabinet (LWH) mm (1370) Dimensions of control cabinet (LWH) mm (1370) Suitable for Carat * Suitable for Carat * Suitable for Carat under certain conditions Suitable for Carat under certain conditions * Track motion required Subject to change without notice. 12

13 BuhlSpray. Technical data. Model 2M 6/2 V1600 H1600 V1800 H1800 V2000 H1600 V2000 H1800 Vertical stroke mm Horizontal stroke mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool Flextool Flextool Flextool Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power kw Dimensions of sprayer (LWH) mm Weight of die spray unit kg Suitable for Carat Suitable for Carat under certain conditions Model 3M 8/4 V1800 H1600 V2000 H1600 V2000 H2000 V2500 H2000 Vertical stroke mm Horizontal stroke mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool Flextool Flextool Flextool Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power kw Dimensions of sprayer (LWH) mm Weight of die spray unit kg Suitable for Carat Suitable for Carat under certain conditions Model 3M 8/4 V2500 H2500 VT2000 H1600 VT2500 H2000 VT2500 H2500 Vertical stroke mm Horizontal stroke mm Number of spray-blow circuits Number of die release agents No. of high-pressure blow circuits Spray head Flextool Flextool Flextool Flextool Drive type AC-Servo AC-Servo AC-Servo AC-Servo Connected power kw Dimensions of sprayer (LWH) mm Weight of die spray unit kg Suitable for Carat Suitable for Carat under certain conditions Subject to change without notice. 13

14 BuhlLadle. Technical data. Model 1_12 Model 2_23 Model 3_60 Ladling volume per cycle kg (Al) Horizontal travel mm Bath level descent mm Connected power kw Dimensions of ladling unit (LWH) mm Weight of ladling unit kg Height adjustment of casting cell mm Ladling accuracy % +/ 1.5 +/ 2 +/ 2 Control system DataView DataView DataView Suitable for Carat* Suitable for Carat under certain conditions * * Data based on type Carat compact Subject to change without notice. 14

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16 Carat. Technical data / dimensions. Injection unit Machine type Injection force, dynamic (90 % injection stroke) Injection force, intensified Plunger diameter (min. / max.) Shot position Shot weight (Al) Plunger (min./ max.) stroke filling rate 60% Projected area, plunger diameter (min. / max.) Projected area at 400 bar Specific injection pressure (min. / max.) kn kn mm mm mm kg cm ² cm ² bar 105 lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / extended / / / / / lean / / / / / compact / / / / / lean / / / / / compact / / / / /

17 Closing unit Maximum locking force Platen size (height width) Distance between tie bars Die height (min. / max.) Die opening stroke Ejector force Ejector stroke Machine weight Machine dims. incl. safety gates (l w h) kn mm mm mm mm kn mm kg m / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / Subject to change without notice. 17

18 Carat. Technical data / dimensions. MQ MC MP MO MH min/max MB MF MG MG MH ML MJ MN MI MK MA MD ME Machine type* MA MB MC MD ME MF MG MH MI MJ min. MJ max. MK ML MN MO MP MQ Units in mm * Data based on type Carat compact Subject to change without notice. 18

19 We make the Carat your solution tailored to your part and your individual requirements.

20 Bühler AG DC en CH-9240 Uzwil Switzerland T F die-casting@buhlergroup.com buhlergroup.com/die-casting

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