The correct control and measurement of the vacuum process and its correct interpretation are the key to effective production improvement. Data collection is a way to ensure the best analysis of the vacuum process.

Introduction Today, vacuum technology plays a key role in the production of complex high-quality castings and structural components. Nevertheless, in order to ensure an efficient vacuum process, Fondarex aims to consider a complete die casting process. The quality of the casting depends on the sealing and precision of the mold, the quality of the alloy, the lubrication and temperature regulation technology, the sealing between the piston and the injection sleeve, the parameters and efficiency of the die-casting machine, and an adequate vacuum system (Figure 1). Vacuum die-casting requires a complete grasp of the pressure die-casting process and vacuum technology. Any deviation, such as leakage, incorrect parameter settings, or even improper vacuum system size or integration, can have a significant impact on the quality of cast parts. Every project starts with the analysis of the mold. As an expert in vacuum application research, Fondarex will provide suggestions in the following areas:

– Gating system design – Vacuum channel layout – Set up vacuum devices, such as vacuum valves or cooling blocks, according to the project and customer needs. – In terms of investment in vacuum systems based on castings and technical requirements, we think it is important to consider which strategy is more suitable for the setup. Either a mobile vacuum system (Figure 2) or a unit vacuum system (Figure 3) may be suitable, but according to the factory layout, die casting machine size range and casting range, Fondarex will accompany customers to recommend the most cost-effective solution. The advantages of vacuum For many years, vacuum technology has proven the necessity of high-efficiency production in many high-end products (Figure 4). Vacuum is no longer a new technology, but it is still one of the technologies that is continuously improved and has a positive impact on the casting process and casting quality at the same time. Thanks to the vacuum technology (Figure 5), the largest pores are removed, which leads to better thermal management and no blistering of cast parts even at high processing temperatures.

Vacuum process control Fondarex attaches great importance to enhanced and reliable vacuum process control (Figure 6). The purpose is to provide adequate control of the vacuum method and to correctly interpret the measured values. Fondarex provides the following main process controls

– Continuous measurement of vacuum in the mold (inside the vacuum valve or on top of the cooling block) (Figure 7) – Control of real-time vacuum parameters to achieve the best vacuum curve relevant to the project – Continuous measurement of the vacuum in the tank – Continuous measurement of filter contamination – Continuous measurement of the contour of the cooling block – Continuous air flow control for each vacuum channel – Measurement of the amount of evacuated air per injection – Continuous quality control of the evacuated air – Control of vacuum humidity – Control of mold tightness – Consumption of compressed air Control-Control of power consumption-Control of vacuum pump performance Data collection of vacuum process Fondarex manages vacuum process data at different levels. First, record the data and measurement curve in the Siemens automation system of the vacuum system (Figure 8). From there, Fondarex offers the option of transferring data and measurement curves to a computer or die-casting machine via Profinet, Profibus or Ethernet communication interfaces. In order to use the vacuum system in the easiest way, Fondarex has integrated vacuum process control on multiple die casting machine brands (Figures 9 and 10). These technical possibilities combined with the experience of Fondarex employees have led to continuous improvements in the control and analysis of the vacuum die casting process (Figure 11). Based on this expertise, Fondarex launched "Industry 4.0" as its next equipment, which can evaluate the stability and performance of the vacuum die casting process and determine the quality of cast parts. Fondarex attaches great importance to data collection, but in fact it pays more attention to the correct interpretation of these data in order to provide a concise production report including the quality of castings in the future. Conclusion Fondarex vacuum technology enables a high degree of flexibility in the integration of die casting units. In addition, the Fondarex device is compatible with all die-casting machines and is suitable for every project, providing a complete analysis of the vacuum process and finally presenting the possibility of modern data transmission.

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