Die casting machine PLC is a digital operation electronic system, it controls the automatic operation process.
In die-casting machines, Programmable Logic Controller (PLC) is a key equipment widely uses in industrial automation control. PLC achieves precise control over various operational aspects of the die-casting machine through its powerful logic operations, sequential control, timing, counting, and arithmetic operations.
Programmable logic controller(PLC) of die casting machine usually includes input modules, processing modules and output modules. They are set and monitored through human-computer interaction interfaces. It has 5 main functions as below:
- Automatic control
- Parameter setting and storage
- Temperature measurement
- Fault diagnosis and maintenance
- Extended function
The role of PLC in die-casting machine
The main function of PLC in die-casting machines is to replace traditional hard wired relay control systems and provide more reliable and flexible control methods.
According to modern die-casting machines typically use PLC control to achieve automated management of the die-casting process. For example, PLC can control various stages of a die-casting machine, including mold closure, injection, holding, cooling, and mold opening operations. Through programming, operators can flexibly adjust the sequence and parameters of these operations, thereby optimizing production efficiency and product quality.
Die casting machine PLC automatic control
It can automatically control each operation step of die casting process, thereby improving production efficiency and product quality. For example, in low-pressure casting machine, PLC system realizes precise control of casting process through connection with switch quantity module and relay module. It has below advantages:
High reliability
The PLC control system adopts modular design, which improves the stability and reliability of the system. The literature mentions that PLC control systems have advantages such as high dependency, high anti-interference ability, and low power consumption.
High precision
The PLC control system can achieve high-precision control, as mentioned in the literature, with a feeding accuracy of 1m ± 0.01mm.
Easy to maintain
The PLC control system adopts a modular design, which is easy to maintain and expand. The literature mentions that PLC control systems have the advantage of being easy to maintain.
Economy
PLC control system can improve production efficiency, reduce energy consumption, and thus enhance economic benefits. The literature mentions that PLC control systems have advantages such as high economy, stable operation, easy maintenance, and low power consumption.
Die casting machine PLC parameter setting and storage
Programmable Logic Controller (PLC) system can set relevant parameters through human-computer interaction interface module.
And it can also store the process parameters of casting each workpiece in personal computer. So as to analyze specific batches of products and better promote production.
In a high-pressure casting machine (HPDC) usually includes the following steps:
The general process of setting PLC parameters
- Define node list: Firstly, it is necessary to clarify the nodes that need to be monitored and controlled, such as alarms, machine status, production data, hydraulic systems, cycle times, etc.
- Set time interval: Set the time interval for data collection through the “Set Interval” node to ensure real-time and accurate data.
- Connect data source nodes: Connect various data source nodes (such as alerts, machine status, production data, etc.) to the system for subsequent processing.
- Subscription data: Connect a “Subscription” node after each data source node to subscribe to and retrieve data.
- Data aggregation: All subscribed data is ultimately aggregated into a node called “PLC HPDC Machine”, which is marked as “active subscribed” to indicate that it is actively subscribing to these data.
- Counter settings: Set counter nodes (such as “Seng Counter” and “Source Description”) to record message counts and data source descriptions.
These steps ensure that the PLC can obtain and process various data from the high-pressure casting machine in real-time and accurately, thereby achieving efficient control of the production process.
Parameter storage technology
Internal storage
EEPROM: stores key process parameters such as pressure and temperature thresholds, with a lifespan of approximately 10000 erasures and no loss during power outages.
Optimization strategy: Floating storage design to reduce frequent local writes.
External Extended Storage
SD card: stores large capacity data (such as production records, fault logs), connected to PLC (-41) through SPI or I ² C interface.
Temperature measurement
The basic concept and function of PLC (Programmable Logic Controller) temperature measurement in die-casting machines is to collect and process real-time data from temperature sensors (such as thermocouples) through the PLC system to achieve precise control of mold temperature.
PLC reads temperature signals and combines them with preset control logic (such as PID algorithm) to achieve closed-loop temperature control, ensuring temperature stability during the die-casting process and improving product quality and production efficiency.
Mold temperature control
PLC collects real-time mold temperature data through sensors, and combines PID control algorithm to adjust the cooling water flow rate, achieving precise control of mold temperature.
Pouring temperature control
During the die-casting process, the temperature of the molten metal has a significant impact on the quality of the casting and the lifespan of the mold. PLC can be used to control the temperature of the melting furnace, ensuring that the temperature of the molten metal is within the set range.
Heat treatment temperature control
During the heat treatment process of die-casting molds, PLC can be used to control the temperature and vacuum degree of vacuum heat treatment.
Cooling system control
PLC can be used to control the operation of the cooling system, ensuring that the flow and temperature of the cooling water meet the process requirements.
Fault diagnosis and maintenance
Programmable Logic Controller (PLC) system has strong reliability and anti-interference capabilities. Enable it to effectively perform fault diagnosis and maintenance in the die-casting machine and reduce downtime.
Extended function
The PLC system has strong scalability. It can expand its functions by adding digital modules, analog modules, etc. to adapt to different production needs.
Haichen die casting machine
Haichen is one Chinese die casting machine manufacturer. We produce high pressure die casting machines for more than 10years. Haichen produces both cold chamber die casting machine and hot chamber die casting machine. They are all have durable working and highly precise features.
Haichen die casting machine programmable logic controller can accommodate new part designs easily by programming and adjusting the program without requiring large-scale hardware changes.
Die casting machine PLC can improves production efficiency and product quality. Moreover, it also provides strong support for the automatic control of die-casting machines. It is mainly reflected in its high reliability and flexibility.
