CONTROL SYSTEM FOR CONTROLLING FLOW OF COOLING FLUID IN A DIE
CASTING ASSEMBLY
CROSS-REFERENCE TO RELATED APPLICATION(S)
I [001] This application is related to Indian Provisional Patent Application Serial No
3819/DEL/2012 filed on 12/12/2012 entitled "A Method and Syster, of Cooling for Use in
Industry" and incorporated herein by reference in its entirety
TECHNICAL FIELD
[002] The present invention generally relates to control systems, and more specifically, to a
control system for controlling a flow of cooling fluid to one or more core pins in a die casting
assembly. Further, the present invention relates to a method of controlling the flow of cooling
fluid to the one or more core pins in the die casting assembly.
BACKGROUND 1
[003] Die Casting is a manufacturing process in which a molten metal/alloy is injected, under
high pressure, into a hardened steel die, also called mold Die casting machines typically employ
6 two or more mating dies which together define a mold cavity correspording to a shape and size
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of a part to be molded In their simplest forms, one of the two dies is axially moved towards the
? other to close the mold and is axially moved away from the other to open the mold for removal
1 of the molded part
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[004] In some cases, it may be desirable to cool the mold and the metal/alloy within it as
I quickly as possible after the mold cavity has been filled to permit removal of the part without
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i distortion in shape and/or structure To this effect, dies are sometimes water-cooled The
production rate of a given die-casting machine is directly affected by the rapidity with which the
molded parts are cooled to a temperature suitable for their removal from the mold.
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1 2 OEC 1013 ' * [005] In some cases, parts may be molded with a hollow interior in order to meet one or more
requirements of an application. In other cases, the parts may need to be molded to define
passageways or conduits extending therethrough. To manufacture such parts, one or more core
pins may be provided in the dies forming the mold. The core pins extend into the mold cavity to
create the required internal configuration, for example, hollow interior, or conduits.
.[006] In cases where a large diameter core pin is employed to form a relatively large hollow
portion in the part, cooling of the core pin may be performed by manufacturing the core pin in a
hollow configuration, and spraying an interior of the core pin with a suitable cooling solution, for
example, water. However, when small diameter core pins are used to form a small internal
configuration in the molded parts, it may be dificult to spray cooling solutions into an interior of
such core pins and provide cooling thereto. In the past, recognition of this limitation has led to
the utilization of stainless steel as a preferred material for the core pins. However, during
operation, the casting machine may experience prolonged cycle times with use of stainless steel
core pins. The prolonged cycle time may be sufficient to permit dissipation of heat by conduction
from the core pins to an external sink. While it is possible to produce precision casting parts with
use of such a system, the relatively long cycle times may cause the production rate of the die
casting machines to be low.
[007] Moreover, during operation, stainless steel core pins tnay transition a wide range of
temperatures leading to soldering and wash-out on outer walls of the core pins. Soldering refers
to the reaction of iron, for example, stainless steel, and a molten metal such as aluminium, and is
typically characterized by the formation of the inter-metallic phases over the die material. In
cases where aluminium is used as the molten alloy, the reaction between tool steel (usually H13)
and the aluminium may cause inter-difision and formation of intermetallic phases. Therefore,
soldering or formation of such inter-metallic phases over the die mate ial may render the core
pins unfit for subsequent casting cycles and present difficulties in obtaining high quality
precision parts from the die casting machine. In addition to soldering, non-uniform cooling of the
molten metallalloy around the core pins may lead to formation of isolated pools of liquid or
molten form of the metallalloy and may cause "Shrinkage porosity" effect around the core pins.
[008] The aforesaid problems are typically minimized by making the core pins hollow and
flowing pressurized water through them However, it may be subsequently required to terminate
the water flow afier a certain amount of time to achieve optimum temperature at the core pins
during casting process as excess cooling of the core pins can cause otb:i:r difficulties in the die
casting process.
[OW] Many systems have been developed in the past to control a flow of cooling fluid in the
core pins. However, with use of some of the previously known systems, small amount of water
may dribble from the discharge line even after the supply of cooling fluid has been turned off.
Such dribbling of cooling fluid in and around the core pins can cause steam formation on the
internal walls of the mold and cause a quality of the molded parts to deteriorate over time and
.use.
[0010] Other known systems typically use separate hydraulic and pneumatic control devices to
pressurize water and air respectively. Moreover, the hydraulic control devices therein may
include conventional water pumps and motors to pressurize water. Such devices may
subsequently employ different electrical control systems for controlling a working of the pump,
motor and the pneumatic control systems Therefore, configurations r ; the previously known
systems may be rendered complex for installation and use Further, use of such previously
known systems may entail additional costs associated with power, operation, and maintenance.
[0011] In light of the foregoing discussion, there exists a need for a system that overcomes the
aforesaid problems, and provides for better and accurate control in the flow of cooling fluid at
the core pins, as compared to previously known systems.
BRIEF SUMMARY
[0012] The present disclosure seeks to provide a control system for controlling the flow of
cooling fluid to one or more core pins in a die casting assembly.
[0013] The present disclosure also seeks to provide a energy efficient and cost-effective method
of controlling the flow of cooling fluid to the one or more core pins in th:. die casting assembly.
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[0014] In one aspect, embodiments of the present disclosure provide a control system for
controlling the flow of cooling fluid to the one or more core pins in the die casting assembly. The
control system includes an air supply line, a water supply line, and a programmable logic
controller (PLC). The air supply line includes at least one air booster for pressurizing air at high
pressures in the air supply line, and a first solenoid valve located upstream of the air booster for
injecting water at high pressure using highly pressurized air The water supply line includes a
second solenoid valve disposed therein The second solenoid valve is configured to release air
from a water filling line duringlbefore a water fill process. The PLC is coupled to the first
solenoid valve and the second solenoid valve. The PLC is configured to control an operational
mode of the first and second solenoid valves.
[0015] The control system also includes a third solenoid valve installed in a water filling line
disposed parallel to the water supply line. The third solenoid valve is operable by the PLC to fill
water in the water filling line after an air purge process of the last process cycle completed.
Optionally, the third solenoid valve is operable by the PLC to fill water in the water filling line
before a successive cycle of water injection in the core pins.
[0016] The control system additionally includes a fourth solenoid valve installed in an air purge
!ine disposed parallel to the air supply line. The fourth solenoid valve is operable by the PLC to
control the supply of pressurized air for purging water from the core pins after the water injection
cycle.
[0017] In one embodiment, the control system hrther includes an Alternating Current (AC)
noise filter, a Direct Current (DC) noise filter, and a Switch Mode Power Supply (SMPS)
communicably coupled to the AC noise filter and the DC noise filter. The SMPS is configured to
convert AC power from the AC noise filter into DC power for supply into the PLC, text panel
and other control equipments via DC noise filter.
[0018] In an aspect of the present disclosure, the control system further includes a first pressure
guage, and a second pressure guage. The first pressure guage is located upstream of the air
booster and configured to measure a pressure of the supply air. The second pressure guage is
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located downstream of the air booster and configured to measure the pressure of output air i.e.,
highly pressurized air.
[0019] Additionally, the water supply line of the control system may further include a third
pressure guage and a fourth pressure guage. The third pressure gauge may measure a pressure of
water supplied into the water supply line while the fourth pressure gauge may measure a pressure
of water supplied to the pin cores .i.e., Cooling water
[0020] Optionally, the air supply line and the water supply line may further include filters
installed therein. The filters may be configured to prevent impurities from entering into the
associated air and water supply lines.
[0021] In an aspect of the present disclosure, the the air booster of the control system is
configured to pressurize air without use of mechanical and electrical power.
[0022] In yet another aspect, embodiments of the present disclosur! provide a method of
controlling the flow of cooling fluid to the core pins.
[0023] Embodiments of the present disclosure substantially eliminate the aforementioned
problems in the prior art, and enable the user to control and/or monitor various operations of the
control system in an effective manner. Further, the control system of the present disclosure uses
less power, and hence, entails lower operating costs as compared to existing systems of the prior
art. Furthermore, the control system disclosed herein mitigates various other problems known to
.exist with systems of the prior art. These problems may include, but are not limited to, inaccurate
metering of water or air during the cooling process, vibrations and electrical shocks from
operation of the pump or motor, and frequent maintenance of the components present in the
existing systems of the prior art.
[0024] Additional aspects, advantages, features and objects of the present disclosure would be
apparent from the drawings and the detailed description of the i:'.~strative embodiments
construed in conjunction with the appended claims that follow.
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[0025] It will be appreciated that features of the present disclosure are susceptible to being
combined in various combinations without departing from the scope of the present disclosure as
defined by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] For the purpose of illustrating the present disclosure, exempli~~c~oyn structions of the
disclosure are shown in the drawings. The summary above, as well as the following detailed
description of illustrative embodiments, is better understood when read in conjunction with the
appended drawings. However, the present disclosure is not limited to the specific methods and
instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings
are not to scale. Wherever possible, like elements have been indicated by identical numbers.
a [0027] Embodiments of the present disclosure will now be described, by way of example only,
: with reference to the following diagrams wherein
1
Fig 1 is a perspective view of an exemplary housing configured to enclose a control system of
the present disclosure,
Fig 2 is a rear orthogonal view of the exemplary housing of Fig 1,
Fig 3 is a schematic illustration of the control system, in accordance with an embodiment of the
present disclosure,
Fig 4 is a schematic illustration of an electrical circuit diagram employed by the control system
1 of Fig 3, and
Fig 5 is a method of controlling a flow of cooling fluid to one or more core pins in a die casting
assembly, in accordance with an embodiment of the present disclosure
[0028] In the accompanying drawings, an underlined numeral or alpha-numeral is employed to
represent an item or component over which the underlined numeral or alpha-numeral is
positioned or an item to which the underlined numeral or alpha-numeral is adjacent. A nonunderlined
numeral or alpha-numeral relates to an item identified by a line linking the nonunderlined
numeral or alpha-numeral to the item When a numeral or alpha-numeral is nonI
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' underlined and accompanied by an associated arrow, the non-underlined numeral or alphanumeral
is used to identify a general item at which the arrow is pointing
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DETAILED DESCRIPTION
[0029] The present disclosure relates to a control system for controlling a flow of cooling fluid
to one or more core pins in a die casting assembly Referring now to the drawings, particularly
by their reference numbers, Fig. 1 is a perspective view of an exemplary housing 1 configured to
enclose a control system 3 of the present disclosure as shown and described in conjunction with
Figs. 3-4 In an embodiment as shown in Fig. 1, the housing 1 is box-shaped and suitably sized
to enclose the various components of the control system 3. Although a box-shaped housing is
shown in Fig. 1, any shape and size commonly known in the art may be - .sed to form the housing
1 such that the housing 1 is configured to enclose the various components of the control system
3. Therefore, it is to be noted that a shape and size of the housing 1 is merely exemplary in nature
and hence, non-limiting of this disclosure.
[0030] The exemplary housing 1, as shown in Fig. I, may be provided with a handle l a on a top
side thereof. Additionally, handles l j may be affixed to a front side of the housing 1. Handles la
and lj may be configured to allow easy handling of the housing 1. Optionally, the housing 1 may
.be provided with fixtures, brackets, and other structures commonly known in the art to allow
easy installation of the housing 1 in an industrial setting for example, a factory shop floor. Many
structures are commercially available and may be readily employed by a person ordinarily
skilled in the art for facilitating the handling and/or installation of the housing 1. Hence,
explanation pertaining to such structures is omitted from the present disclosure.
[0031] The housing 1 may include a connector l c to receive electr ;a1 power therein. The
connector l c may be configured to receive universally standardized forms of alternating current.
In one exemplary embodiment, the connector lc may receive AC electrical supply of 220V,
50Hz for operation of the control system 3. Alternatively, in another exemplary embodiment, the
connector l c may receive AC electrical supply of 1 IOV, 60Hz for operation of the control
system 3.
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'[0032] The housing 1 may be further provided a switch l b The switch l b is disposed in electric
communication with the connector lc. As shown in Fig. 4, the switch l b is connected to the
connector lc by wires. The switch lb is configured to prevent or allrw routing of electrical
power through the control system 3. Although it is disclosed herein that the connector lc may be
configured to receive universally standardized forms of alternating current, in some
embodiments of the present disclosure, the switch lb may be a selector switch additionally
configured to switch ON the standardized form of electrical power for supply to the control
system 3.
[0033] Referring to Fig. 2, the housing 1 is additionally provided with a grounding port 2a The
grounding port 2a is adapted to connect with an earthing wire or an insulation source. Moreover,
one or more installation and/or operating instructions may be shown via stickers 2b provided on
the housing 1. The installation and/or operating instructions may include safety manuals
providing information on positioning and installation procedures for the housing 1 in addition to
explaining safety protocols while operating the control system 3.
[0034] Turning back to Fig. 1, the control system 3 of the present discl:lsure can be operated in
manual mode or set to an auto-sequence mode depending on specific application requirements of
a die casting process. The mode of operation can be selected from various buttons and/or
controls provided on a text pad lh as shown in Fig.1 and Fig.4. While settings and process
parameters pertaining to the auto-sequence mode can be selected using the text pad lh, the
housing 1 is also provided with a shot signal connector Id to receive first or second shot signal
from a die casting machine (not shown). Therefore, the shot signal connector Id assists the
control system 3 in interfacing with the die casting machine and allows operations of the control
system 3 to synchronize with operations of the die casting machine
[0035] The housing 1 may be provided with three pilot lights 11, lm, and l k mounted thereon.
Pilot light lm may indicate that the control system 3 is powered on. Pilot light 11 may indicate
that the control system 3 is set to auto-sequence mode as the current operational mode. Pilot light
lk may indicate that the auto cycle with the die casting machine is initialized and/or is in
progress. Although three pilot lights 11, lm, and l k are shown and desclibed in conjunction with
* ~ i 1~, it. is to be noted that the number of pilot lights employed to indicate various operations of
the control system 3 may vary from one application to another depending on specific
requirements of the application.
[0036] The housing 1 is additionally provided with an air connection port If. The air connection
port If is adapted for connection with a source of air supply (not shown). Similarly, a water
connection port lg is provided on the housing 1, wherein the water connection port lg is adapted
for connection with a source of water supply (not shown). Instructions pe-taining to supply of air
and water at the respective connection ports If, lg may be provided on a panel le of the housing
1. These instructions may be complied with to meet minimum operating requirements of the
control system 3 and/or to ensure smooth operation of the control system 3.
[0037] The housing 1 may be further provided with a silencer port In to allow connection with
an air silencer (not shown). The silencer port In and the air silencer may be disposed in fluid
communication with the air connection port If. When installed at the silencer port In, the air
silencer may attenuate any noise generated from a movement of air in the housing 1.
[0038] As shown in Fig. 2, the housing 1 is additionally provided with an air purge port 2c and a
cooling water discharge port 2d. Referring to Figs. 1-2 and as best shown in Fig. 3, the air purge
port 2c and the cooling water discharge port 2d are disposed in selective fluid communication
with the air connection port If and the water connection port 1g respectively. The air purge port
2c and the cooling water discharge port 2d are disposed in fluid corr:.nunication with one or
more cores of a die assembly (not shown). Therefore, the air purge port 2c and the cooling water
discharge port 2d are configured to selectively allow egress of air and water from the control
system 3 into the core pins of the die assembly (not shown).
[0039] Referring to Fig. 4, the control system 3 of the present disclosure includes an AC noise
filter 4b. An input side of the AC noise filter 4b is connected to the switch lb by wires 40 and
41. The AC noise filter 4b is used to filter any unwanted signal from the AC supply input. The
control system 3 of the present disclosure includes an SMPS (Switch mode power supply) 4c
connected to an output side of the AC noise filter 4b via wires 42 and 43. The SWS 4c is
configured to convert the 220V or llOV AC signal to a 24V DC signal. Further, the control
'system 3 additionally includes a DC noise filter 4d connected to the the SMPS 4c As shown in
Fig. 4, wires 44 and 45 are used to connect an input side of the DC noise filter 4d to an output
side of the SMPS 4c. The DC noise filter 4d rectifies any noise from the DC signal supplied by
the SMPS 4c
[0040] The control system 3 further includes a programmable logic control (PLC) 4 disposed in
electrical connection with an output side of the DC noise filter 4d and the text pad lh. As shown
in Fig.4, the output side of the DC noise filter 4d is used to power up the PLC 4 via wires 46 and
47, the text pad lh via wires 48 and 49 besides other electrical components present at the PLC
output module side of the control system 3. Further, as shown in Fig. 4, the PLC 4 and the text
pad lh are connected by a communication cable 4e.
[0041] Referring now to Fig. 3, the control system 3, disclosed herein, includes an air supply
line HI. The air supply line H1 may be configured to receive air at a *)ressure typically in the
range of 4 bar to 6 bar. The air supply line HI includes at least one air booster Bl for
pressurizing the air in the air supply line H3. The air supply line H3 hrther includes a first
solenoid valve Vl located upstream of the air booster B1. The first solenoid valve V1 is
i configured to allow water injection at high pressure into the core pins of the die assembly using
highly pressurized air
[0042] In an embodiment of the present disclosure, the air booster B1 is configured to pressurize
air without the use of mechanical and/or electrical power. Many pneumatic pressure boosters that
operate without the use of mechanical or electrical power are readily available and commercially
sold under various proprietary trademarks belonging to business entities such as, but not limited
to, SMC Pneumatics Limited, FESTO, and Ingersoll Rand. Thus, the air booster B1 may be
selected from any of the aforementioned pneumatic pressure boosters and implemented in the
control system 3 to beneficially operate without the use of mechanical or ~:lectrical power.
[0043] The control system 3 hrther includes a water supply line H6. The water supply line H6
includes a second solenoid valve V2 disposed therein. The second solenoid valve V2 is
configured to release air from a water filling line H7 duringlbefore a water fill process.
1[0044] Optionally, in an embodiment of the present disclosure. the air supply line HI and the
water supply line H6 may fbrther include filters (not shown) installed therein. The filters are
configured to allow air, with little or no impurities to enter therethough, and therefore prevent
impurities from entering into the associated lines H1 and H6. A person having ordinary skill in
the art will appreciate that provision of filters in a hydraulic or pneurn:~tic system is known to
prolong a service life of the components therein and allow smooth functioning of the associated
system
[0045] The control system 3 further includes a third solenoid valve V3 installed in the water
filling line H7 disposed parallel to the water supply line H5 and H6. The third solenoid valve is
operable to fill water in the water filling line H7 after an air purge process of the last process
cycle completed and before a successive cycle of water injection in the core pins.
[0046] Referring to FIG. 3, the control system 3 additionally includes a fourth solenoid valve
V4 installed in an air purge line H2 disposed parallel to the air supply line Hl. The air purge line
H2 may be additionally provided with a non-return valve NRV-1 located downstream of the
fourth solenoid valve V4 The non-return valve NRV-1 is configured to allow a uni-directional
forward movement of air through the air purge line H2 and prevent any backward flow therein.
The fourth solenoid valve V4 is operable to control the supply of highly pressurized air in the air
purge line HlO. The air supplied in the air purge line HI0 may be used to purge water from the
core pins after the water injection cycle.
[0047] As shown in Fig. 3, each of the solenoid valves Vl-V4 is disposed in electrical
communication with the PLC 4. The solenoid valves Vl-V4 are individually operable to perform
their respective functions as mentioned herein. In an embodiment, the control system 3 may
additionally include one or more pressure guages (not shown). In one exemplary embodiment,
'four pressure guages namely - a first, second, third and fourth pressure gauge may be employed.
The first pressure guage may be located upstream of the air booster Bl and configured to
measure a pressure of supply air. The second pressure guage may be located downstream of the
air booster B1 and configured to measure the pressure of output air from the the air booster Bl
i.e., highly pressurized air.
[0048] The third pressure guage may be located in the water supply line H6 and configured to
measure a pressure of water supplied into therein. The fourth pressure guage may be located
downstream of the second and third solenoid valves V2, V3 and configured to measure a
pressure of water supplied to the core pins in the die casting assembly. The pressure guages,
disclosed herein, may assist in monitoring the various pressures of air and water in the associated
iines for optimum performance of the control system 3.
INDUSTRIAL APPLICABILITY
[0049] Explanation pertaining to working of the hydraulic and pneumntic components in the
control system 3 will be made hereinafter in continued reference to r'ig. 3.Since the overall
operation of a die casting machine is well known and is not changed to incorporate the present
invention. The details of operation of the die casting machine and the apparatus used to move the
one of the two dies towards and away from one another to close and open the mold, respectively
have not been shown or described. Any conventional die casting machine may be used for this
purpose.
[0050] During the casting process, hot melted aluminium alloy is injected at high pressures into
a mold cavity of the die assembly with the help of a plunger. This injection of the hot melted
aluminium alloy may be carried out in two or three different phases or speeds depending on
, specific requirements of an application. These phases or speed sequences are also called shots
I When a forward shot or a first shot is initiatied, the auto cycle may get activated in the control
system 3 Consequently, the pilot light lk may switch on while the valves V2 and V3 may get
actuated after a predefined time set up at the text pad lh or as determir :d by the auto-sequence
mode of the control system 3
[0051] As disclosed herein, the second and third solenoid valves V2 and V3 are configured to
release air from water filling line and to fill water in the water supply lines H5 and H7
respectively. As per a specific requirement of water during the casting process, one or both
solenoid yvalves V2 and V3 can be selected to operate in the process. The selection, disclosed
may be made with the help of the text pad lh. Cooling fluid, dinclosed herein as water
may preferably include distilled water obtained from the shop floor
[0052] The water is supplied from the shop floor side through water supply line H6 to a junction
T3. Referring to Fig. 3, the junction T3 is disposed upstream of the second and third solenoid
valves V2 and V3. From an output side of the second and third solenoid valves V2 and V3, water
is supplied to the non-return valves NRV-3 and NRV-4 which are configured to allow an
unidirectional forward flow of the supplied water The output of NRV-3 and NRV-4 are
connected at junctions T2 and T4 through lines H5 and H7. Moreover, the junctions T2 and T4
are connected through a connection line HS. After leaving the junction T4, the water is supplied
through an outlet pipe H9 to a manifold (not shown) in fluid communication with the core pins
of the mold cavity.
[0053] The third solenoid valveV3 is maintained open for a predefined period of time or until a
required amount of water is attained in the core pins. Thereafter, third solenoid valve V3 is
closed. The period of time disclosed herein may also be set with the help of the text pad l h as
shown in Figs. 1 and 4.
[0054] At the end of the predefined period of time, the second and third solenoid valves V2 and
V3 are closed. Simultaneously, the first solenoid valve V1 is turned open to allow pressurized air
in the line H4. Air is typically supplied at junction TI from the shop floor. This air is preferably
clean and dry air with the pressure ranging between 4 - 6bars. From TI air is supplied into two
paths through pneumatic pipes HI and H2. Through pipe H1 air is supplied to air booster which
hrther boosts the air to a required level, the setting can be adjusted as per requirement from the
booster via a air regulator provided at the top of the air booster.
[0055] As disclosed earlier herein, the input side of the first solenoid valve Vl is in fluid
communication with the air booster Bl via air supply line H3. As disclosed earlier herein, the air
booster Bl is configured to boost the pressure of air without using any external mechanical or
electrical power. The pressurzied air is routed from the air booster B1 to first solenoid valve Vl
through air supply line H3. The pressurized air is made to flow past the first solenoid valve V1,
the non-return valve NRV-2 and reach junction T2 via line H4. Further, the pressurized air is
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vmade to flow past the junction T2 and reach junction T4 via the connection line H8 Thereafter,
the pressurized air flows through the outlet line H9 and the cooling water discharge port 2d as
shown in Fig. 2. The cooling water discharge port 2d is maintained in fluid communication with
the pin cores in the mold cavity of the die casting assembly.
[0056] The time duration required for the aforesaid water discharge or water injection operation,
i.e. the pressurized air used to pressurize water through the core pins and cool the core pins in the
die casting operation, may also be set with the help of the text pad lh as shown in Fig.1. After a
predefined period of time, the first solenoid valve V1 is closed by the PLC 4. Thereafter, the
fourth solenoid valve V4 is opened by the PLC to perform purging of water.
[0057] As is the case with operation of the air booster Bl and the first solenoid valve Vl, air
from the shop floor may be supplied to the junction TI. Thereafter, the air is made to flow
through the air supply line H2 and reach the fourth solenoid valve V4. The air is made to flow
past the the fourth solenoid valve V4 and is egressed at the air purge port 2c as shown in Fig. 2.
As disclosed earlier herein, the air purge port 2c is maintained in fluid communication with the
manifold associated with the core pins. Therefore, air from the air purge port 2c is configured to
purge the water from the core pins. A time duration associated with this operation may also
predefined with the help of the text pad 1h as shown in Figs. 1 and 4.
[0058] Fig. 5 illustrates a method of controlling the flow of cooling flu' ; to the core pins of the
die casting assembly. At step 502, the method 500 includes supplying water to the core pins via
the cooling water discharge 2d of the control assembly 3, wherein the cooling water discharge
port 2d is disposed in selective fluid communication with the core pins. At step 504, the method
500 firther includes terminating the supply of water from the cooling water discharge port 2d to
the core pins At step 506, the method 500 further includes injectively pressurizing the water by
sequentially supplying air through the air booster Bl, wherein the air booster B1 is disposed in
selective fluid communication with the cooling water discharge port 2d At step 508, the method
500 further includes terminating the supply of air from the cooling water discharge port 2d upon
reaching a pre-determined value of pressure in the core pins. At step 510, the method 500 further
includes supplying air to the core pins via the air purge port 2c, wherein the air purge port 2c is
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disposed in selective fluid communication with the core pins. At step 512, the method 500
fbrther includes purging the mixture of pressurized air and water supplied to the core pins via the
cooling water discharge port 2d.
[0059] It should be noted here that the steps 502 to 512 are only illustrative and other
alternatives can also be provided where one or more steps are added, one or more steps are
removed, or one or more steps are provided in a different sequence without departing from the
scope of the claims herein. However, in a preferred embodiment of the present invention, the
step 512 is performed after step 506 by closing the cooling water discharge port 2d and
sequentially opening the air purge port 2c.
[0060] Implementation of the control system 3, disclosed herein, may reduce exorbitant costs
incurred with use of previously known systems. The present control system 3 may reduce costs
associated with installation, operation, and maintenance as compared to the previously known
systems. Further, embodiments of the present disclosure can be used to mitigate operational
inefficiencies associated with use of previously known systems. The control system 3 may
effectively prevent dribbling of water from the core pins by supplying air through the air purge
port 2c and removing any water droplets remnant in the core pins after the water injection cycle.
Consequently, it may be possible to obtain defect-free andlor high quality parts casted by the die
.casting machine.
[0061] Further, with regards to operation of the control system 3, an operator of a die casting
machine may conveniently input process parameters pertaining to the control of cooling fluid
through the core pins. Furthermore, various other options such as auto-sequence mode and autocycle
initialization are provided in the control system 3. The operator may beneficially use such
options individually or in combination with other programs to control '';e flow of cooling fluid
through the core pins.
[0062] Modifications to embodiments of the present disclosure described in the foregoing are
possible without departing from the scope of the present disclosure as defined by the
accompanying claims. Expressions such as "including", "comprising", "incorporating",
"consisting of', "have", "is" used to describe and claim the present disclosure are intended to be
ORIGINAL -
1 2 OEC 1013 'I ..;3 3 -.
DR. 1 2 '
% L.U. J
construed in a non-exclusive manner, namely allowing for items, components or elements not
explicitly described also to be present Reference to the singular is also to be construed to relate
to the plural
Dated this 1 2Ih day of December, 20 13
BHATIA, Rahat
(Abhinav Bhalla)
lN/PA - 1885
of B.R.Bhalla & Associates
Attorneys for the Applicant
u
I claim
ORIGINAL
1. A control system for controlling a flow of cooling fluid to one or more core pins in a die
casting assembly, the control system comprising:
an air supply line comprising:
at least one air booster for pressurizing air in the air supply line; and
a first solenoid valve located upstream of the air booster for injecting
water at high pressure using highly pressurized air; and
a water supply line comprising a second solenoid valve disposed therein, the
second solenoid valve configured to release air from a water fillir ;: line duringtbefore a
water fill process; and
a programmable logic controller (PLC) coupled to the first solenoid valve and the
second solenoid valve, the PLC configured to control an operational mode of the first and
second solenoid valves.
2. The control system, as claimed in claim 1 , further comprising a third solenoid valve
installed in a water filling line disposed parallel to the water supply line, wherein the third
solenoid valve is operable by the PLC to fill water in the water filling line during at least
one of
after an air purge process; and
before a successive cycle of water injection in the core pins
3. The control system, as claimed in claim 1, further comprising a fourth solenoid valve
installed in an air purge line disposed parallel to the air supply line, wherein the fourth
solenoid valve is operable by the PLC to control the supply of air lor purging water from
the core pins after the water injection cycle
4. The control system, as claimed in claim 1, further comprising:
an Alternating Current (AC) noise filter;
a Direct Current (DC) noise filter; and
a Switch Mode Power Supply (SMPS) communicably coupled to the AC noise
filter and the DC noise filter, SMPS configured to convert AC power from the AC noise
filter into DC power for supply into the DC noise filter.
5. The control system, as claimed in claim 1, wherein the control system further comprises:
I 38 1 5 ORIGINAL o 8
6 1 2 OEC 20\3
a first pressure guage located upstream of the air booster, he first pressure guage
configured to measure pressure of supply air; and
a second pressure gauge located downstream of the air booster, the second
pressure gauge configured to measure a pressure of output air from the air booster.
6. The control system, as claimed in claim 1, wherein the water supply line fbrther
comprises:
a third pressure guage configured to measure a pressure of water supplied into the
water supply line; and
a fourth pressure guage configured to measure a pressure of water supplied to the
pin cores.
7. The control system, as claimed in claim 1, wherein the air supply line and the water
supply line fbrther comprise filters installed therein, the filters configured to prevent
impurities from entering into the associated lines.
8. The control system, as claimed in claim I, wherein the air booste. is configured to
pressurize air without use of mechanical and electrical power.
9. A method of controlling a flow of cooling fluid to one or more core pins in a die casting
assembly, the method comprising:
(a) supplying water to the core pins via a cooling water discharge port of a control
assembly, the cooling water discharge port disposed in selective fluid
communication with the core pins;
(b) terminating the supply of the water from the cooling water discharge port to
the core pins;
(c) injectively pressurizing the water by sequentially supplying air through an air
booster, the air booster disposed in selective fluid communication with the
cooling water discharge port;
(d) terminating the supply of air from the cooling water discharge port upon
reaching a pre-determined value of pressure in the core pins;
(e) supplying air to the core pins via an air purge port of the control assembly, the
air purge port disposed in selective fluid communication with the core pins;
and
(0 purging the mixture of pressurized air and water supplied to the core pins via
the cooling water discharge port.
10. The method, as claimed in claim 9, wherein the step (0 is performed after step (c) by
closing the cooling water discharge port and sequentially opening the air purge port.