MOTION SYSTEM APPLICATIONS
Sensors and transducers
in die casting and more
Sensors and transducers for motion designs and related systems abound. Consider the monitoring of mold deformations in aluminum die-casting. Here, inductive eddyNCDT displacement sensors from Micro-Epsilon use eddy currents to track gaps in aluminum die-casting processes. These precision sensors increase the service life of the tools involved and product quality, while rejects and expenses are reduced. Their robust sensor design also enables gap measurements in harsh ambient conditions. In the production of aluminum die-cast parts, liquid aluminum is pressed into a mold under high pressure. The two mold halves must be held together with significant force. Despite this high contact force, the tool halves are pressed apart minimally. This process is also called mold breathing. Although minimal openings are normal and intended during this process, a gap causes fraying on the component if it is too large. These splinters must be reworked to meet the high quality requirements of the final product. If aluminum residues remain on the tool, they also lead to increased wear, which reduces tool life. Monitoring tool deformation using inductive displacement sensors based on eddy current enables high product quality combined with improved tool life and reduced rework. Usually, three to four eddyNCDT 3005 eddy current systems are used to ensure consistent gap monitoring at several measuring points. A system consists of a compact and robust controller, which together with the cable and sensor form a unit. The integrated system design increases robustness and resistance to external factors, making the system insensitive to high temperatures, dust, dirt or pressure, and delivers accurate results regardless of the environment.
The compact design of Micro-Epsilon eddyNCDT 3005 sensors mean they can integrate into existing machines. PLASTIC INJECTION MOLDING FORCE FEEDBACK
Mold core
Stationary platen
Clamping motor Rear platen
Molded part
LCF Series load cell
CLAMPING CONTROL WITH SENSORS
Consider another application of sensors in die casting as well as IAAA Series amplifier injection molding. During these additive-manufacturing processes, the mold is clamped together to resist the rapid thermal expansion and contraction caused by the molten material filling the mold PLC cavity. Flawed parts can be created if the mold is not kept properly data acquisition clamped to resist thermal loading throughout the molding and USB Series Here, FUTEK’s LCF Series universal casting process. To mitigate pancake load cells pair with an IAA Series these thermal effects, some analog amplifier for feedback into a PLC. designs include pancake load The sensor provides force feedback for cells at the clamp contact precise control over a plastic injectionpoints — enabling a machinery molding process. monitoring processes to adjust clamping forces.
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DESIGN WORLD — MOTION
Sensor & Transducers - MC 11-19 V3.indd 76
11 • 2019
Mold cavity
IHH500 and IPM650 digital displays
motioncontroltips.com | designworldonline.com
11/18/19 3:21 PM
