Casting machines

INDUGA-KWC machines consist of the portal machine frame, manipulators, furnace, blackwash bath and electric control. To fulfil the different capacity requirements, a full range of machines with one or two manipulators and one or two riser tubes can be supplied. A choice of freely programmable controls is available: Beckhoff, Allen Bradley, Siemens or Mitsubishi. No foundation or platform is required for the setting up of the machine

LPDC 0012 (Semi-automatic machine)

This machine stands out for its automatic casting process by low pressure technology combined with manual die manipulation. The main advantage of this concept is superior quality of low pressure die casting, achieved at lower investment costs. To reach the maximum capacity, up to four operators with up to four identical or different dies can work simultaneously.

The working principle of the machine:

Manual setting of die with cores on the manipulator. Swivelling over onto the furnace and automatic casting
Removing die from the manipulator, opening it to remove the casting
Cleaning, cooling and coating of die in a blackwash bath
Core setting and moving die back to the manipulator

The most important factor to get a good quality of brass casting is the filling process of the die. This operation is done by modern, fully computerised low pressure die casting technology. The manipulation of the dies remains manual. Manual furnace charging with solid material. Charging of liquid material is possible.

LPDC 1011

Fully automatic machine with linear portal, one manipulator and one furnace

Cycle time 45-50 sec.
Capacity per shift (8 hours) approx. 500 castings

This machine stands out for its high capacity and its easy operation and maintenance.

Manual setting of the cores
Automatic casting with computer controlled pressure-time curve
Automatic unloading of the casting
Cooling and coating in a blackwash bath

The furnace can be selected for a melting capacitiy of 300 or 500 kg per hour. Manual or automatic furnace charging with solid material. Charging of liquid material is possible.

LPDC 2021

Fully automatic machine with rotary portal, two manipulators and one furnace

Cycle time 37-42 sec.
Capacity per shift (8 hours) approx. 650 castings

This machine stands out for a high production rate and the possibility of using two different dies at the same casting temperature.

The working principle of the machine:

Manual setting of the cores for both manipulators at the same place
Automatic casting with computer controlled pressure-time curve
Automatic unloading of the casting
Cooling and coating in a blackwash bath

The furnace has a melting capacity of 500 kg per hour. Manual or automatic furnace charging with solid material. Charging of liquid material is possible.

LPDC 2121

Fully automatic machine with rotary portal, two manipulators and one furnace.

Cycle time 32-37 sec.
Capacity per shift (8 hours) approx. 800 castings

This machine is an "upgraded" design of the LPDC 2021 and stands out for its two independent drive units for each manipulator. During the stop of one of the two manipulators for cleaning or die charging, the second manipulator continues its work.

The working principle of the machine:

Manual setting of the cores for both manipulators at the same place
Automatic casting with computer controlled pressure-time curve
Automatic unloading of the casting
Cooling and coating in a blackwash bath

The furnaces have a melting capacity of 500 kg per hour each. Manual or automatic furnace charging with solid material. Charging of liquid material is possible.

Casting machine components

Control

Control cabinet with freely programmable PC control of the machine by Beckhoff industrial PC and touch screen for machine operation. The pressure build-up can be individually programmed and memorized. The casting speed depends on pressure and is programmed and regulated according to the geometry of the castings. On the touch screen error messages as well as important production data are shown.

Manipulator

The new manipulator stands out for a new guiding system with heavy duty roller rail system. The manipulator movements are actuated by hydraulic cylinders. The die closing stroke is 10 kN. Maximal die dimension 500x400 mm

Induction furnace

Channel induction furnace with 3 inductors
Melting capacity alternatively 300 or 500 kg/hour
Water and air cooling
Content of : 1800 kg

Blackwash bath

Temperature controlled cooling/blackwash bath of stainless steel with two separate baths and agitators.

Workpiece removal

Automatic casting removal ejecting from die and dropping on a stainless steel sliding table. The sliding table moves the castings to the backside of the machine. As an alternative to the removal table a gripper on a robot for accurate positioning can be offered.

Die cleaning

The cleaning unit consists of two shot blasting stations, each for one half of the die.

Core shooting machines

Cores must satisfy all kinds of requirements, such as resistance, limitation of gas evolution during the casting process as well as a simple, clean removal of cores after casting. The quality of the sand, the chemicals and their mixture is very important. INDUGA-KWC-Engineering AG supplies two different versions of core shooting machines for casting of faucets.