COLD CHAMBER DIE CASTING MACHINES

PacMar Cold Chamber Die Casting Machine Illustrated

PacMar cold chamber die casting machines are fast, economical, reliable and durable. The design is technologically innovative. The construction is rugged and precise. The machines are versatilely controlled by industrial standard ISA computers. The build-in shot-monitoring-system allows user to decipher the black art of die casting clearly. The running sequence of the machine is conveniently user programmable.

CLAMPING SYSTEM

Assembling Machine is regarded as one of the most important step and is tightly scrutinized

TOGGLE: Top and down two toggle design are proven, reliable and delivers strong and even locking force.

PLATEN: All three platens are made out of extra thick precision machined cast steel (Newer models use 500 MPa tensile strength ductile iron, please specify when ordering.) The innovative moving platen design eliminated the traditional maintenance prone ejector supporting rods and effectively connected the moving platen into a box unit to provide rigid and strong support.

Transmission Housing Die Cast on PacMar Machine

TIE BAR: PacMar tie bars are made out of forged Hard-Chrome-plated and particular grounded high strength Chrome alloy steel. A innovative strain relief grove is designed to reduce the risk of tie bar breakage due to un-even die thickness. Fully automatic tie bar pull are available as an option.

LOW-PRESSURE-DIE-CLOSING: All PacMar machine come with a unique low pressure die closing circuit. It can be activated to protect your precious tooling investment. When activated, the platen will close at low pressure, until both die face touched to turn into high pressure to lock up the die. If foreign object, such as sticky runner, flashing, bent ejector pins were on the die face, the die closing will stop and machine will alarm operators to check the die face.

The Side Mount Safety Ratchet

SAFETY: The mechanical hatchet bar, activated by mechanical safety door closing, is located on top of the clamping system to prevent accidental die closing. Accumulators are eliminated from the die locking circuit for safety. PacMar use modern designed hydraulic fluid regenerative circuit to accelerate the die closing speed and to reduce cycle time. In addition, it takes four hydraulic valves energized simultaneously to close the die. Safety is our first concern.

EJECTION SYSTEM:

The ejector mount plate and moving platen are designed into one box-like piece to provide strong support and maintenance-free operation

Hydraulic powered ejection is smooth, powerful and responsive. The stroke is programmable. The delay is programmable. The repetition is programmable for multiple ejection. With optional proportional hydraulic circuit, even the ejection forces are programmable.

INJECTION SYSTEM:

Model C-630 Cold Chamber Die Casting Machine

The injection system is designed for consistent, fast and powerful shots. The intensification cylinder is connected in tandem to the injection cylinder. The fluid path from the accumulator to the shot cylinder is carefully designed and machined for smooth unobstructed fast flow to achieve the fast and responsive injection system PacMar is famous for. On certain models, the fast injection velocity exceeds 9 meters per seconds, or, about 360 inches per seconds.

Model C-630 With Helper-Side Mount Extractor

The injection cylinder end cap is the hydraulic manifold. The injection accumulator is mounted right on the cylinder end cap. The hydraulic flow path is carefully calculated and engineered to achieve high flow. The interior of the hydraulic passage in the manifold is purposely roughed to a degree to achieve laminar flow to reduce flow resistance to ensure fast shot velocity.

Automatic Ladler

ACCUMULATORS: There are two independent piston type accumulators for fast injection and for intensification. The accumulator air bottle volume is carefully calculated to balance with the volume of the hydraulic fluid to achieve fast flow and to maintain the consistent pressure.

THREE SHOT SPEEDS: There are three injection speeds. The slow speed is controlled by a directional solenoid valve. The medium and fast shot valves are controlled by cartridge valves for their high and stable flow rate and low pressure lose. For example, the size of the fast and medium shot valve on model C-800 machines are 100 mm and 63mm cartridge valves respectively. When fully opened, they together will deliver over 10,000 liters per minutes or 2,630 gpm of massive hydraulic flow. Which will push the injection cylinder to a lightening speed of over 320 inches per seconds.

Our technicians treat their work with great respect

Each shot speeds can be individually controlled. The starting (change-over) of each shot speeds can be programmed on screen using the transducer or by repositioning the limit switches. These change-over positions will be sorted with die parameters memory once it is set.

INTENSIFIER: The intensification system is designed for fast responsive and reliability. The typical pressure rise time is less than 35 milliseconds. The PacMar intensification system comes with its own accumulator, flow control and pressure control. The starting of the intensification is three way controlled by the combination of reaching the limit switches position, sensing the slowing of the plunger from the transducer and monitoring the resistance (pressure) from the injection cylinder pressure transducer. When plunger passes the limit switch, the controller computer starts watching the cylinder hydraulic back pressure and the velocity of the plunger, if pressure rises and the velocity slows, the control computer turns on the intensification valve and start the intensification process.

Installing A Tie Bar Nut

In order to open the intensification cartridge valve within 10 milliseconds to achieve the pressure rise within 35 milliseconds, PacMar carefully engineered a multiple valve array to fast open the cartridge valve and to bring up the intensification pressure before gate solidify.

Experienced user with precise ladler can choose to let die casting machine controller decide when to start intensification automatically. The die cast machine compares the previous shot data and decide the optimum pressure and location to turn on the intensification.

Die Height Adjusting Mechanism

ONE PRESSURE SYSTEM: The intensification system use oversized cylinder and regular system pressure to intensify the injection pressure. The intensification accumulator stores regular system pressure fluid to reduce the risk of accident and to avoid using costly extra equipments on two pressure system.

THREE SHOT POSITIONS: The injection positions can be changed from center to 2 different positions below center easily. Lift cylinder is provided. Position is located using spacer blocks.

HYDRAULIC CORE PULL

THREE SETS OF CORE PULL are provided as standard features on model-C machines. Any core pull can be placed at any part of the machine cycle. Each set has its own control and (optional) flow adjustment. With the optional core-pull-accumulator user can creatively use the core pull to drive squeeze cylinders for squeeze casting or biscuit cutter cylinders, or turn it into a giant multi-slide or even multi-injection machines.

HYDRAULIC SYSTEM

Model C-1600

DUAL pump is used to deliver dual high-low pressure through pressure induced unloading, the system can deliver high flow and high pressure without adding extra horse power. The system will automatically un-load all pumps when at idle to conserve energy and to avoid hazard.

DIN MOUNT STANDARD VALVES:

1250 ton die casting machine

All of the control solenoid valves are of standard DIN-24-340 sub plate mount, now ISO-4400, mounted on a custom made high efficient low resistance flow manifold. There are four manifolds on the machine. One for system pressure control and die open close. The second one is located on the middle of the machine and provides power to ejection and core pull. The injection manifold and intensification manifold are located right at their corresponding cylinders.

All cartridge valves used on PacMar machines comply to ISO-7368 standard for worldwide compatibility.

ELECTRICAL SYSTEM

Assembling Moving Platen

OPERATOR PANEL: The operator switch panel is mounted on a free standing pedestal and can be positioned to anywhere convenient. Alternatively, fixed platen mount operator switch panel can be chosen instead of pedestal mount.

SOFT MOTOR START is provided to reduce the starting amperage demand. When motors are starting, the hydraulic circuit will unload all pressure to reduce the start up power required.

ZERO CROSSING SWITCHING: All control solenoid are turned on and off by zero crossing circuit to avoid electric spikes and eliminate EMS noises. The result is extra long life solenoid and smooth operation.

Assembling Machine In Progress

ISA COMPUTER: PacMar machines are controlled by a standard industrial computer (ISA). The standard ISA computer parts are available all over the world. There are lot of technicians and control engineers in many different fields knows and services the ISA industrial computer.

NETWORK READY: The control computer is ready for networking. For multiple machine users, their machines can be linked together using the standard Ethernet hardware into a PacMar engineering station. The engineering station can further be connected into your enterprise network, your WAN or even to Internet. Your CEO or strategic customers can view the machines in production from anywhere in the world in near real time.

We take price in our precision

STANDARD I/O: The controller I/O (Inputs and Outputs) system is interfaced through four standard 24-bits Gray Hill SSR (Solid State Relay) field wiring boards. Those SSRs are all solid state circuits and are available in many electrical control supply house (such as Grainger) as standard shelf items.

PROGRAMMABLE MACHINE SEQUENCE: The machine cycling sequence can be easily user programmed. User will go into a pass word protected sequence programming screen, pull together the machine functions and arrange them in sequence the way they want than save it with the current die number (or name). It need to be done only once. Yet it is so useful and powerful. User can creatively program the machine to do many job that was thought to be impossible before.

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I/O SCREEN: Control system has build-in test screen to view all the I/Os by its names of their current state. This screen can be used for diagnosis and learning purpose. It can also be used to control I/O directly from the key board with proper pass word and safety satisfaction. This provides a very powerful tool to inspect machine functions and allow users to quickly pin point to the site of malfunctioning. PacMar was the first one to invent this feature. It is now been imitated by others without the full feature.

MACHINE SELF DIAGNOSIS: The control system has build-in self diagnosis function. It uses programmed human logic to constantly check functions of the machine while it is running to eliminate potential damages to the machine and to ensure casting quality.

SHOT MONITOR SYSTEM

The Lubrication Grease is Distributed Evenly to Every Joints Using this Pressure Distribution Device

PROFILE POINTER: There is a thin vertical line to the shot profile called profile pointer. This line enables user to "walk" through the profile. The pointer appears as soon as user press one of the four arrow keys on the keyboard. User can use move the pointer to any position on the graph. The screen will display, as the profile pointer moves, the exact time mark of that pointer position along with shot pressure, distance of plunger traveled and shot velocity. User can easily use this tool to calculate the gate velocity, the fill time and figure out the feed condition on a multiple cavity die. It is the tool to decipher the black art of die casting.

900 ton machine

SHOT PROFILE MEMORY: One set of standard shot profile can be stored with die parameters memory. It can be used in die set up to fine tune your shot condition to be exactly the same as the previous set up.