The main functions of the sprayer in die casting are lubrication of the mold, cooling, and demolding. Types include automatic, servo, two-axis, internal spraying, etc.
The technical features include precise control, programmability and integration. It is used in high-volume applications such as automotive parts, copper alloy die-casting, etc. It should be noted that different models are suitable for different tonnages and materials. The servo spraying machine is energy-efficient and efficient, and internal spraying reduces waste.
When selecting a sprayer for die casting, focus on the following critical criteria and standards to ensure compatibility with your production needs, while avoiding reliance on specific model examples:
Key Selection Criteria
- Nozzle & Spray Performance
- Flow Rate/Pressure Compatibility: Choose a sprayer with adjustable flow rate (e.g., 5–30 L/min) and pressure range (0.3–1.5 MPa) to match mold size and release agent requirements.
- Atomization Precision: Prioritize sprayers with atomized droplet sizes ≤50μm to minimize release agent waste and ensure uniform coating.
- High-Temperature Resistance: Opt for nozzles made of materials (e.g., 316L stainless steel, ceramic-coated) that withstand temperatures ≥200°C for die casting environments.
- Automation Integration
- Robot Compatibility: Ensure compatibility with industrial robots (e.g., KUKA, Fanuc) via communication protocols (e.g., Profinet, EtherCAT) for dynamic spray path programming.
- Closed-Loop Control: Select sprayers with real-time feedback systems for flow rate and pressure to maintain process consistency.
- Functional Flexibility
- Multi-Mode Spraying: Support for point, line, and surface spraying modes to adapt to complex mold geometries (e.g., deep cavities, narrow gaps).
- Quick-Change Systems: Modular gun designs enabling multi-nozzle swaps within 10 minutes for faster mold changeovers.
- Cost & Energy Efficiency
- Energy-Saving Design: Prioritize servo-driven sprayers, which reduce energy consumption by 30%+ compared to pneumatic systems (target power use ≤3 kW/h).
- Release Agent Efficiency: Use high-precision metering pumps (error ≤±2%) to minimize agent consumption (target ≤50 ml per cycle).
- Compliance & Safety
- Adhere to standards like China’s JB/T 12284 or Europe’s EN 12981 for safety and performance, including explosion-proof and pressure resistance certifications.
Alternative Solutions
- Customization: Share mold drawings and process parameters (e.g., spray area, cycle time) with suppliers to develop tailored solutions.
- Brand Recommendations:
- European Brands: Focus on energy-efficient servo-driven sprayers (e.g., Striko, Dürr).
- Japanese/Korean Brands: Prioritize high-precision atomization control (e.g., Yushin, Toyo).
- Domestic Alternatives: Consider CE/UL-certified manufacturers (e.g., Haichen,LK Group, Yizumi).
Validation Steps
- On-Site Testing: Request sample machines to verify spray coverage and residue levels (target residue ≤0.1 mg/cm²).
- Performance Metrics:
- Measure release agent consumption per cycle (target ≤50 ml/cycle).
- Evaluate equipment reliability (target MTBF ≥5,000 hours).
By aligning with these criteria, you can select a sprayer that optimizes efficiency, reduces costs, and integrates seamlessly into automated die casting lines.
Haichen Sprayer in Die Casting machine
The Haichen sprayers integrated into die-casting machines are a critical component of Haichen’s comprehensive die-casting solutions. These sprayers are designed to apply release agents or lubricants onto mold surfaces, enhancing production efficiency and product quality. Below is an overview of their key features and functionalities:
1. Role and Configuration of Sprayers
Haichen’s sprayers are explicitly listed as part of its die-casting equipment portfolio. They work in tandem with core components (e.g., die-casting machines, molds, and extractors) to form a complete production line. Key functions include:
- Lubrication: Ensures smooth mold operation and prevents sticking during demolding.
- Temperature Control: Regulates mold surface temperature to minimize thermal stress and defects.
- Extended Mold Lifespan: Reduces wear and tear by maintaining consistent lubrication.
2. Nozzle Types and Optimization
Haichen offers customizable nozzle designs tailored to specific production requirements:
- Y-Type Nozzles: Ideal for complex mold cavities, enabling multi-directional spray coverage for uniform coating.
- Pinch Nozzles: Use a “pinching” mechanism to control flow rate, minimizing overspray and improving precision.
- High-Pressure Nozzles: Engineered for high-accuracy applications, paired with robust pressure control systems.
Nozzle selection depends on factors like alloy type, mold geometry, and quality standards (e.g., high-pressure nozzles for precision automotive parts).
3. Technology Integration and Quality Assurance
Haichen’s sprayers benefit from advanced systems that ensure reliability:
- Precision Control: Imported industrial-grade controllers and servo-driven hydraulic systems enable accurate spray timing and pressure adjustments.
- Material Durability: Critical components (e.g., steel nozzles) undergo heat treatment and wear-resistant coatings to withstand harsh conditions.
- Energy Efficiency: Features like accumulator pressure-boosting systems reduce energy consumption while maintaining performance.
4. Comprehensive Support Solutions
Haichen provides end-to-end support to optimize sprayer integration:
- Mold Flow Simulation: Pre-production analysis to refine spray patterns and minimize material waste.
- Technical Expertise: On-site engineering support for installation, calibration, and troubleshooting.
- Rapid Spare Parts Delivery: Reduces downtime by supplying wear-prone components (e.g., seals, nozzles) promptly.
Overall
Haichen’s sprayers exemplify their commitment to innovation and quality in die-casting technology. By combining versatile nozzle designs, precision engineering, and robust materials, these sprayers enhance process efficiency, reduce defects, and contribute to long-term cost savings. As part of Haichen’s holistic solutions, they are a vital asset for industries demanding high-performance die-casting, such as automotive and consumer electronics.
Features of Haichen die casting sprayer
1.Easy to use
User-friendly control
Haichen adopts centralized operation, and you can easily save programming steps for future use. Since its settings are the same as the operating philosophy of your die casting system, you can avoid additional training costs. Haichen spray sequences can be used with HCD-H hot chamber and HCD-C cold chamber die casting machines (30 to 30800 kN) and saved in each mold program, which speeds up mold changes.
2.Coordinated process flow
Easy to program
You can program Haichen spray machines via a handheld device with a screen, making it easier to coordinate your spray process flow from any angle.
3.Increase productivity
High-performance spraying tools
You can choose the right Hai’chen high-performance spraying tools for your specific application. These tools are designed to reduce the spraying time of the mold, thereby increasing the overall productivity of the system.
