DIECAST-CHECK by InfraTec: Ensuring Thermal Safety in Die Casting Processes
With InfraTec’s new DIECAST-CHECK automation solution, users can monitor the temperature distribution across the surface of the die inline. The system detects thermal deviations early on, thereby creating the conditions necessary to stabilize die casting processes, reliably ensure the quality of castings, and reduce scrap.
Unlike spot measurements using pyrometers or thermocouples, DIECAST-CHECK provides a complete thermographic image of the mold surface that shapes the casting (“cavity”). This makes it possible to identify critical areas of the die and make targeted corrections during the ongoing process. The thermographic measurements also provide important data for optimizing the quality of the die cast part and the cycle time of the process.
The recorded temperature data can also be processed for each individual production cycle using AI-based algorithms. This makes it possible to analyze patterns in mold temperature across different batches and, for example, draw conclusions about how to heat the mold more evenly.
Temperature Deviations as Sources of Error in Die Casting
Die casting is a highly productive process for the mass production of components made of non-ferrous metals such as aluminum and magnesium, as well as their alloys. The processes take place within narrow thermal windows and with short cycle times. Even slight temperature deviations on the cavity surface can compromise the quality of the casting. These deviations occur particularly during the warm-up and start-up phases of a system. Reliable inline temperature monitoring is therefore essential for ensuring an efficient process.
Reliable Measurements in Demanding Environments
As part of the DIECAST-CHECK solution, high-resolution thermal imaging cameras reliably detect temperature deviations, even on complex, finely structured components. However, non-contact, area-wide temperature measurement during the die casting process is technically very challenging due to the harsh environmental conditions. To make it easier to remove the component after die casting, the mold is sprayed with a release agent before each casting operation. The optical systems of the thermal imaging cameras used in the immediate process environment must be protected from the resulting spray mist and dirt.
To meet the particularly demanding requirements of this “lubrication phase,” a special, highly robust protective housing was developed in collaboration with an industry partner. This housing features a precisely controlled protective flap and an air-purge system that prevents contamination of the germanium protective window integrated into the housing. This ensures the continued functionality of the entire measurement system, and cleaning becomes necessary only after long periods of operation.
DIECAST-CHECK Software: Temperature Monitoring, Alarms, and Process Evaluation
The automation solution is integrated into the die casting cell’s process control system via industry-standard interfaces. The DIECAST-CHECK software used is a version of InfraTec’s INDU-SCAN software specifically tailored to the monitoring of die casting processes. It delivers data to the higher-level plant control system, displays the process data on a control screen, and stores all measured values.
Temperature data is automatically collected and recorded after the release agent is applied. The user interface of the DIECAST-CHECK software displays real-time thermal images of the die. Temperature trends over time can also be displayed graphically and analyzed. For analysis, various regions of interest (ROI) can be defined, enabling targeted monitoring of areas that are particularly critical for component quality.
If the temperature of the die measured by the system is within the specified limits, the die cast part produced is classified as “acceptable” and the cycle continues. If the temperature exceeds or falls below the limits, the system triggers an alarm and highlights the affected areas where temperatures are too high or too low. The data are transmitted to the machine control system, which initiates the necessary heating or cooling of the die.
In addition to temperature, the DIECAST-CHECK software monitors other parameters. These include compressed air supply to the camera protective housing, the proper operation of the protective flap, and the need to clean the viewing window.