HAICHEN cold chamber die casting machine has adopted the advanced hydraulic components from USA and Germany, and equipped with specially designed industrial control system, which can ensure our machine with high speed, short cycle time, easy operation, stability, safety and reliability.
Because our company technology improves constantly, and there may be some contents on the manual will be changed due to technology improvement, please understand.
In order to ensure the safety for operator, give full play to the the efficiency of the machine and extend the service life, in use process, must pay attention to the following four steps:
- Operation Training
- The die casting machine is working
- Machine inspection:
- Safe operation
Operator Training:
Ensure that operators are fully trained in the safe operation of the die casting machine. Training should cover machine controls, emergency procedures, proper handling of molten metal, maintenance protocols, and use of personal protective equipment (PPE).
Note: Push the mold close button with both hands, never with one hand.
Wear appropriate PPE: The operator should wear appropriate PPE, including safety glasses, heat-resistant gloves, face shield, protective clothing, and safety shoes. PPE helps prevent hazards such as molten metal splashing, flying debris, and heat-related injuries.
Cooling water should be injected immediately after the machine is started: when the oil temperature rises above 30°C, the cooling water circuit should be opened promptly. When the ambient temperature is below 0℃ and the downtime is long, oil cooling should be carried out. Close the water inlet of the oil cooler and open the drain pipe to discharge the water in the oil cooler to prevent the cooler from icing and damage.
Note: Cooling water should be fresh water or tap water. Turn off after work.
The die casting machine is working
Keep away from moving parts, high temperature parts and electrified parts and close the protective door. The safety guard door can not only prevent liquid metal splashing and injury accidents in the die-casting process, but also reduce the occurrence of mechanical damage and fire accidents. Therefore, the safety guard door shall not be used or removed arbitrarily during the production process.
No body parts or tools shall be stretched out in the working area inside the drawbar until the machine has come to a complete stop. Do not clean mold cavities, place casting inserts or perform other auxiliary work while the machine is running.
When the machine has an emergency failure (such as overpressure, pipe rupture, oil leakage, etc.), the machine must be stopped immediately, the power supply turned off, and emergency treatment should be carried out for treatment and maintenance. When a fire occurs, the nitrogen in the accumulator should be discharged.
When the operator leaves the machine or stops the machine for a long time, the oil pump should be stopped, and the power supply should be turned off in time after work.
Machine inspection:
Periodically inspect the cold chamber die casting machine for any signs of damage, wear or malfunction. Especially the path switches. If loose or poorly contacted, they should be replaced or repaired promptly. Pay close attention to electrical components, hydraulic system, cooling system and safety features.
Regularly check the lubrication of automatic lubrication: check whether the oil level in the lubrication tank is sufficient before starting the machine, lubricate the manual lubrication part of the machine 1 to 2 times a day and press the lubrication button of the electrical box for 1 minute before starting the machine.
Daily inspection
Check voltage, current, lack of phase, the motor, and cacophony. Check contacts for losing, sparkover, overheat, and repair in time.
Check sensitivity and reliability of all path switch and knobs and bolts, repair when find.
Motor power supply can be cut by emergency knob.
Keep electrical control box cleaning, dry without oil and dust conduction. Keep cleaning and expedite around the machine.
Check position of oil scale before start up the machine. Add the same flame retardant hydraulic oil to the required position.
Check oil temperature after running for a moment and it should be within 35℃~55℃. If it exceeds 55℃, check block in cooling line and the temperature of cooling water. Too high oil temperature will reduce viscosity the oil.
Check pressure and noise of the oil pumps.
Check grease level in center lubrication pump, add when lack.
The machine equipped automatic lubricating, the times and period has been set by computer program. Automatically lubricate once when power on to keep good lubrication of each point.
No matter what mode, manual or automatic, when the protecting door is opened, the action of mould closing will be stopped to protect the operators.
Check pressure in hydraulic system, the Max. value is 13MPa, more than this will damage the machine.
Check pipe works and fittings for leakage.
Check the mould is whether fixed on movable and fixed mould plates.
Check whether the overflowed metal liquid is cleaned well before duty off, to keep all movable parts cleaning.
Weekly check
Check the movable parts wear intensity, lubrication especially continual movable parts. For example, toggle, crossing, copper sheathing and base plate.
Add grease to every grease nipple.
Check path switch and relative bumping.
Check oil leakage, nitrogen pressure in accumulator, if lack, add nitrogen. If the pressure loss is very large in 1 ~ 2 days, replace vesicle and sealing ring in time.
Check fastens in joints.
Monthly check
Check all bolts and nuts including hydraulic, mechanism, electrical, air accurate and fasten and adjust them.
Check whether the hydraulic oil is polluted. Check whether the filter element is blocked.
Annually check
Clean out the oil filter every half a year, and check the block. Here is the way to clean out: 1) anticlockwise loosen the center mandril of the oil filter with a spanner; 2) dismount the 6 M8 bolts; 3) open the cover, use two M8 bolts pack out the strainer and launder it with diesel oil
Clean out every half a year the interior of the copper pipe and channel of the cooler, to prevent it from furring.
Clean out pipework of the cooling system, and eliminate rust, furring, and impurity annually. Rinse the pipe with compressed air or nitrogen gas.
Check whether replaces hydraulic oil.
Check whether the wire is aging. Check the terminals and tie-in of the wire.
These are some of the issues that should be noted about the safe operation and maintenance of cold chamber die casting machine. If there is more you want to know, please feel free to consult us.
Safe operation
Before the machine stops completely, no body part or tool can stretch in the working area inside the tie bar.
Never clean the die cavity, place the casting insert, and do other auxiliary work when the machine running.
Check, maintain, and test (once per shift normally) the die-casting machine and its safeguards, When the safe performance is repaired, check the mechanical, electrical, and oil circuit parts thoroughly, open and close the guard gates many times, and check all travel switches for sensitivity.
The temperature of hydraulic oil must be under 55℃, oil level should be above the middle of the oil window a little, check regularly.
Stop to check when it is more than 55℃, or oil tends to degenerate, seals tend to damage, and the service life of the pump will be reduced.
When the machine is installing the die-casting mould, adjust it in the “manual” mode.
When the “automatic” mode is used at the beginning of a working cycle, set the machine to its original state, viz.
opening the mould completely, ejecting back completely, injecting back completely, and pulling the core completely if any, and then starting the “automatic” procedure.
Within the allowable range of die-locking force, and situations that can meet the requirement of die-casting processing, reduce the die locking force properly to prolong the service life of the machine.
During the initial manual operation, if any abnormality between the molds is found, release the die-closing buttons of both hands immediately to check and repair.
The parallelism between the first platen and the second platen has been calibrated before delivery, the user needs no adjustment.
Only when long-term service or overhaul needs it adjusted.
If the noise from the oil pump is too loud, stop the pump, and check the filter element of the oil filter for jam or the oil suction pipe for air leak. Clean the oil filter at the oil pump inlet port frequently, and the oil suction pipe should not leak.
Keep the electrical protection devices and safe protection devices perfect or stop the machine to repaired.
The electrical box should be dampproof, heat insulation, and keep the elements working normally.
Check the high-pressure rubber pipe regularly, and replace it when find leakage.
Check the accumulator regularly. Carry out exterior macroscopical at least once a year, interior crack detection per 2 years, and pressure test per 3 years. For pressure containers that have been used for more than 10 years, check annually. Test and adjust according to the methods that are recommended by the manufacturers.
Please do not exceed the rated pressure; no drainage is permitted. Reduce pressure in the accumulator to 0 if disassembly is necessary. Only qualified personnel can carry out the repair, installation, reassembly, replacement; and load off When the machine is not stopped entirely, any part of the human body should not enter the die joint.
After usage of half a month, fasten bolts including hydraulic, electrical, mechanism, and gas actuating of the new machine. Check flanged, fittings of oil line fixture to prevent leakage regularly.
The safety door can not only prevent the splashing and injury accidents of molten metal in the die-casting process but also reduce the occurrence of mechanical damage and fire accidents, so do not use or remove the safety door at will during the production process.
When installing and disassembling the die-casting mold, the “Manual/Auto” knob should be placed in the “Manual” position for adjustment.
Maintenance:
there are some points for maintenance.
- Nitrogen pressure of the hydraulic accumulator
- Hydraulic oil
- Hydraulic oil tank
- Oil suction filter
- Lubrication system
Fill the central lubrication tank with the required lubricant in a timely manner. An alarm will sound if the lubrication pump fails to pressurize. Restart only after the problem is solved. Or the workpiece may be worn.
Relieve system pressure and nitrogen pressure before servicing accumulators. System pressure must be relieved when removing hydraulic components or lines to the accumulator. Open shut-off valves CV1 and CV2 to release the pressurized oil in the fast injection accumulator and the pressurized accumulator. Open shutoff valves CV3 and CV4 to vent nitrogen when disassembling accumulators and associated parts of the nitrogen line.
Relieve pressure in accumulators when servicing hydraulic systems to ensure safety. When disassembling high-pressure parts such as hydraulic valves and lines, due to residual pressure inside, do not be in a hurry to loosen the screws when unscrewing them, but wait until the residual pressure has been completely released before unscrewing all the screws, otherwise, it will be dangerous.
The die-casting machine has strict requirements for the operator’s safe operation. Proper maintenance of the machine protects the safety of personnel and equipment and helps increase economic efficiency. To ensure the normal operation of the die-casting machine, scientific maintenance should be carried out while using it correctly.
Nitrogen pressure of the hydraulic accumulator
The first inspection is performed after the first week’s service, and then once per half a month within two years, and then once every two months—charge nitrogen in case of pressure lack.
Hydraulic oil
Draw out hydraulic oil in the oil tank for filtration after 500 hours of service of a new machine, and fill in the oil tank again. Replace new oil after 1500 hours. In continuous production, oil temperature should not exceed 55℃ for the long term.
Hydraulic oil tank
When replacing hydraulic oil, clean the oil tank before filling the new oil.
Oil suction filter
Replace once per year.
Lubrication system
For manual lubricating points, add lubricant once per half a month in the first half a year for a new machine, then add once per month. The cycle of central lubrication is set by the computer, add once per 500~700 moulds.
Items of periodical inspection
Conclusion
Haichen has nearly a microcomputer control ERP resource management operation system, and we have passed the ISO9001:2000 international quality management system certification.
If you have any problem during the operation of die casting machine, please feel free to contact us for support, we are committed to solve all problems and providing the best service for you as soon as we can.