DESC:TECHNICAL FIELD
[001] The embodiments herein generally relate to a die casting system and more particularly, to a system and a method for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system to improve product quality and operating condition of die(s).

BACKGROUND
[002] A die casting die (henceforth referred to as die) is used for producing metal castings on a die casting machine (henceforth referred to as machine). The die produces a casting/set of castings per shot. The form of intended features of castings is cut out in the die. The die is mounted on a hot or cold chamber as per design and molten metal is poured/injected inside it. Liquid metal flows into the cavity area to form to the shape of casting during solidification. After solidification the die is opened and casting is ejected out. This solid casting is generally called the "shot”. The process of injecting the metal is also called the “shot”. Castings with shapes varying from the simplest to complex features and geometries are cast by this method.
[003] On the machine, processing parameters at different stages of the production cycle play an important role to control the quality of the castings being produced. These processing parameters may vary for different types of castings and locking tonnage of the machine on which the casting is being produced. These process parameters are generally identified during the die design and are fine-tuned during the die trial and proving stages to arrive at the recommended parameters for production. They require close monitoring during production to control the overall quality of the unit being developed. Deviation from the recommended parameters can lead to rejection of castings, unscheduled and increased maintenance of the die and, eventually, premature failure of the component forming inserts or other parts of the die. Hence, a close monitoring of recommended parameters during production and addressing any deviation from them is necessary for quality production, higher uptime of die and longer die-life. Die casting usually requires monitoring of various parameters at various stages of the process. The parameters from die side are still not tapped owing to complexity in measuring the same continuously in each shot. Usually, these parameters are monitored only intermittently and irregularly by the shop supervisor or manager or die owner. Since, it is not a periodic or systematic monitoring, in most cases it is insufficient and results in damage to the die and product.
[004] Dies often fail while operating at undesired parameters. For the same reasons the rejection percentage of casting is also very high. They also have a limited life owing to thermal fatigue on the casting forming faces which also leads to surface heat checks and surface cracks. For example, in the production environment, owing to human errors or failures of peripherals of the machine, the temperature on the die surface may exist beyond desired values. This can lead to early failure or cracks on the die inserts. Also, change in other processing parameters could lead to changes in the temperature profile on die surface as well as in the surface quality, dimensional stability and porosity of the casting. This also leads to a high rejection rate. Further, it could also lead to failure of the ejection system, slider and result in die surface damage.
[005] Therefore, there exists a need for a system and a method for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system, which obviates the aforementioned drawbacks.

OBJECTS
[006] The principal object of embodiments herein is to provide a system for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system to improve product quality and operating condition of die(s).
[007] Another object of embodiments herein is to provide a method for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system.
[008] Another object of embodiments herein is to provide a system for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system, which provides real time alerts to operator or supervisor or any other person on operation status of die and the die casting machine.
[009] Another object of embodiments herein is to provide a system for monitoring operating parameters in the die casting system, which enables precise controlling of duration of die spray (die lubricant) thereby improving product quality based on the operating temperature of the dies.
[0010] Another object of embodiments herein is to provide a system for monitoring operating parameters in the die casting system, which reduces flashing in dies by monitoring and maintaining better thermal condition of die inserts.
[0011] Another object of embodiments herein is to provide a system for monitoring operating parameters in the die casting system, which increases lifetime of die and also increases uptime of die.
[0012] Another object of embodiments herein is to provide a system which enables precise monitoring the temperature and pressure parameters die(s) and die casting machine(s) against predefined values and creating alerts in the event of violations thereby improving product quality.
[0013] Another object of embodiments herein is to provide a system for monitoring operating parameters in the die casting system, which reduces percentage of rejection of the casting and down time of the die through timely alerts on its running status.
[0014] Another object of embodiments herein is to provide a system for monitoring operating parameters in the die casting system, which enables easy and remote access to current production conditions of the die.
[0015] Another object of embodiments herein is to provide a system for monitoring operating parameters in the die casting system, which maintains history of shot wise production data of all connected dies for assessing production performance, analysis and investigation, establishing relation between casting quality with production conditions.
[0016] These and other objects of embodiments herein will be better appreciated and understood when considered in conjunction with following description and accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0017] The embodiments are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0018] Fig. 1 depicts a schematic diagram of a system for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system, according to embodiments as disclosed herein;
[0019] Fig. 2 depicts an illustration diagram of the system, according to embodiments as disclosed herein;
[0020] Fig. 3 depicts a perspective view of a die, where a first temperature sensor, a second temperature sensor and a first pressure sensor is in communication with a controller unit of a control system, according to embodiments as disclosed herein;
[0021] Fig. 4a depicts a cross-sectional view of a moving insert of the die, according to embodiments as disclosed herein;
[0022] Fig. 4b depicts a cross-sectional view of a fixed insert of the die, according to embodiments as disclosed herein;
[0023] Fig. 4c depicts a cross-sectional view of a slider core of the die, according to embodiments as disclosed herein;
[0024] Fig. 5a depicts an illustration diagram of a die casting machine, according to embodiments as disclosed herein;
[0025] Fig. 5b depicts an illustration diagram of a holding furnace of the die casting machine, according to embodiments as disclosed herein; and
[0026] Fig. 6 depicts a flowchart indicating a method of monitoring operating parameters of die(s) and die casting machine(s) in a die casting system, according to embodiments as disclosed herein.

DETAILED DESCRIPTION
[0027] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0028] The embodiments herein achieve a system for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system to improve product quality and operating condition of die(s). Further, embodiments herein achieve a method for monitoring operating parameters of die(s) and die casting machine(s) in the die casting system. Referring now to the drawings Figs 1 through 6, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0029] The die casting system includes at least one die (D), (as shown in fig. 2, fig. 3 and fig. 4c), a die casting machine (M), (as shown in fig. 2 and fig. 5a) and a holding furnace (MF), (as shown in fig. 5b). The die casting machine (M) includes at least one accumulator (MA) and at least one intensifier (MI), (as shown in fig. 5a). The accumulator (MA) is adapted for driving the plunger and/or charging the casting metal with pressure. Intensifier (MI) is a hydraulic device that increases the hydraulic fluid pressure at the end of the injection stroke.
[0030] Fig. 1 depicts a schematic diagram of a system (100) for monitoring operating parameters of die (D) and die casting machine (M) in the die casting system, according to embodiments as disclosed herein. In an embodiment, the system (100) includes a control system (102), a die temperature sensing system (104), a holding furnace temperature sensor (105), a first pressure sensor (106), an accumulator pressure sensor (108) and an intensifier pressure sensor (110). For the purpose of this description and ease of understanding, the system (100) is explained herein with below reference to monitoring operating parameters of die (D) and die casting machine (M) in a die casting system such as but not limited to a high pressure die casting, a low pressure die casting, a gravity die casting and a hot chamber die casting. However, it is also within the scope of the invention to monitor operating parameters of die (D) and die casting machine (M) in a cold chamber die casting or any other type of die casting systems without otherwise deterring the intended function of the system (100) as can be deduced from the description and corresponding drawings.
[0031] The die temperature sensing system (104) is adapted to detect and communicate temperature of at least one die (D) to the control system (102). For example, the die temperature sensing system (104) detects the temperature of the die (D) before and after die spray (die lubricant process) - two times in a cycle. The control system (102) compares the measured temperature of the at least one die (D) with predefined temperature value(s) and accordingly the control system (102) provide alert(s) if the measured temperature of the least one die (D) is not matching the predefined temperature value(s). The predefined temperature value(s) includes an upper limit and a lower limit. The die temperature sensing system (104) includes a first temperature sensor (104A) and a second temperature sensor (104B). The first temperature sensor (104A) is adapted to be connected to at least one moving insert (DM), as shown in fig. 4a) of the die (D). The first temperature sensor (104A) is adapted to detect and communicate temperature at the at least one moving insert (DM) of the die (D) to the control system (102). The second temperature sensor (104B) is adapted to be connected to at least one fixed insert (DF), as shown in fig. 4a) of the die (D). The second temperature sensor (104B) is adapted to detect and communicate temperature at the at least one fixed insert (DF) of the die (D) to the control system (102). The control system (102) compares the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) with corresponding predefined temperature value(s) and accordingly the control system (102) provide alert(s) if the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) is not matching corresponding predefined temperature value(s).
[0032] The holding furnace temperature sensor (105) is adapted to detect and communicate temperature of molten metal in a holding furnace (MF), as shown in fig. 5b) to the control system (102). For example, the holding furnace temperature sensor (105) detects the temperature of molten metal in the holding furnace (MF) at the start of the injection cycle. The control system (102) compares the measured temperature of the molten metal in holding furnace (MF) with predefined temperature values and accordingly the control system (102) provides alert(s) if the measured temperature of the molten metal in holding furnace (MF) is not matching the predefined temperature value(s), where the predefined temperature value(s) includes an upper limit and a lower limit.
[0033] The first pressure sensor (106) adapted to detect and communicate pressure of oil in a cylinder (DSC) of at least one slider core (DS), as shown in fig. 3 and fig. 4c) of the die (D) to the control system (102). For example, the first pressure sensor (106) detects the pressure of oil in the cylinder (DSC) of the at least one slider core (DS) during slider extraction (core out). The control system (102) evaluates the maximum oil pressure required for stripping of the at least one slider core (DS) of the die (D). The control system (102) compares the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) with predefined pressure value(s) and accordingly the control system (102) provides alert(s) if the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) is not matching the predefined pressure value(s). The predefined pressure value(s) includes an upper limit and a lower limit.
[0034] The accumulator pressure sensor (108) is adapted to detect and communicate pressure of gas in at least one accumulator (MA) of the die casting machine (M) to the control system (102). For example, the accumulator pressure sensor (108) detects the gas in at least one accumulator (MA) of the die casting machine (M) at injection start point during each shot. The control system (102) compares the measured gas pressure in the accumulator (MA) with predefined pressure value(s) and accordingly the control system (102) provide alert(s) if the measured gas pressure of the accumulator (MA) is not matching the predefined pressure value(s), where the predefined pressure value(s) includes an upper limit and a lower limit.
[0035] The intensifier pressure sensor (110) is adapted to detect and communicate pressure of gas in at least one intensifier (MI) of the die casting machine (M) to the control system (102). For example, the intensifier pressure sensor (110) detects pressure of gas in at least one intensifier (MI) of the die casting machine (M) from the start of second phase till completion of third phase during each shot. The control system (102) compares the measured gas pressure in the intensifier (MI) with predefined pressure value(s) and accordingly the control system (102) provide alert(s) if the measured gas pressure of the intensifier (MI) is not matching the predefined pressure value(s).
[0036] In one embodiment, the control system (102) is a cloud computing based control system which includes a controller unit, a memory unit and a cloud system. The controller unit of the control system (102) is provided in communication with the first temperature sensor (104A), the second temperature sensor (104B), the holding furnace temperature sensor (105), the first pressure sensor (106), the accumulator pressure sensor (108), the intensifier pressure sensor (110) and at least one user interface unit (S, C), as shown in fig. 1 and fig. 2). In an embodiment, the memory unit is adapted to store data when internet connection is not available. Further, the cloud system stores the data. The controller unit of the control system (102) sends data to the cloud system and alert(s) are generated through webpages in cloud system and transmitted to at least one user interface unit (S, C) or indicating means if the measured parameters of the die (D) and the die casting machine (M) is not matching the predefined value(s). The measured parameters of the die (D) and the die casting machine (M) is sent by the controller unit of the control system (102) to the cloud system through Wi-Fi or SIM card. The memory unit of the control system (102) records measured parameters of the die (D) and the die casting machine (M) for every shot with date and time and the shot number is created by the cloud system. For the purpose of this description and ease of understanding, the user interface unit (S, C) is a smartphone and/ or computing system. In another embodiment, the control system (102) is a data logger with programmable control (hereinafter called as programmable control system). The control system (102) is adapted to generate shot count, shot summary and machine cycle time based on the measured parameters of the die (D) and the die casting machine (M). The shot count indicates number of shots with respect to a time period. The shot count is a measure of the number of casting product. The shot summary indicates summary of measured and evaluated parameters for selected shot(s). The machine cycle time indicates time period between each shot. The machine cycle time enables the user (operator/ supervisor) to find root case of idle time and to take actions to improve productivity. The user can monitor idle time of machine (M) between shots.
[0037] In another embodiment, the system (100) includes at least one indicating means (not shown) adapted to indicate the alerts to the user based on input(s) received from the programmable control system (102). For the purpose of this description and ease of understanding, the indicating means (not shown) is at least one of a display screen, a flash light and a buzzer.
[0038] Fig. 6 depicts a flowchart indicating a method (200) of monitoring operating parameters of die (D) and die casting machine (M) in a die casting system, according to embodiments as disclosed herein. For the purpose of this description and ease of understanding, the method (200) is explained herein below with reference to monitoring operating parameters of die (D) and die casting machine (M) in a die casting system such as but not limited to a high pressure die casting, a low pressure die casting, a gravity die casting and a hot chamber die casting. However, it is also within the scope of this invention to practice/implement the entire steps of the method (200) in a same manner or in a different manner or with omission of at least one step to the method (200) or with any addition of at least one step to the method (200) for monitoring operating parameters of die (D) and die casting machine (M) in a cold chamber die casting or any other type of die casting systems, without otherwise deterring the intended function of the method (200) as can be deduced from the description and corresponding drawings.
[0039] The method (200) includes,
detecting and communicating by, a die temperature sensing system (104), temperature of at least one die (D) to a control system (102);
comparing by, the control system (102), the measured temperature of the at least one die (D) with predefined temperature value(s); and
alerting by, the control system (102) if the measured temperature of the least one die (D) is not matching the predefined temperature value(s).
[0040] The method step of detecting and communicating by, the die temperature sensing system (104), temperature of at least one die (D) to the control system (102) comprises,
detecting and communicating by, a first temperature sensor (104A), temperature of at least one moving insert (DM) of the die (D) to the control system (102);
detecting and communicating by, a second temperature sensor (104B), temperature of at least one fixed insert (DM) of the die (D) to the control system (102);
comparing by, the control system (102), the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) with corresponding predefined temperature value(s); and
alerting by, the control system (102) if the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) is not matching corresponding predefined temperature value(s).
[0041] Further, the method (200) comprises,
detecting and communicating by, a first pressure sensor (106), pressure of oil in a cylinder (DSC) of at least one slider core (DS) of the die (D) to the control system (102);
comparing by, the control system (102), the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) with predefined pressure value(s); and
alerting by, the control system (102) if the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) is not matching the predefined pressure value(s).
[0042] Further, the method (200) includes,
detecting and communicating by, a holding furnace temperature sensor (105), temperature of molten metal in a holding furnace (MF) to the control system (102);
comparing by, the control system (102), the measured temperature of the molten metal in holding furnace (MF) with predefined temperature values; and
alerting by, the control system (102) if the measured temperature of the molten metal in holding furnace (MF) is not matching the predefined temperature value(s).
[0043] Further, the method (200) includes,
detecting and communicating by, an accumulator pressure sensor (108), pressure of gas in at least one accumulator (MA) of a die casting machine (M) to the control system (102);
comparing by, the control system (102), the measured gas pressure in the accumulator (MA) with predefined pressure value(s); and
alerting by, the control system (102) if the measured gas pressure of the accumulator (MA) is not matching the predefined pressure value(s).
[0044] Further, the method (200) comprises,
detecting and communicating by, an intensifier pressure sensor (110), pressure of gas in at least one intensifier (MI) of the die casting machine (M) to the control system (102);
comparing by, the control system (102), measured gas pressure in the intensifier (MI) with predefined pressure value(s); and
alerting by, the control system (102) if the measured gas pressure of the intensifier (MI) is not matching the predefined pressure value(s).
[0045] Further, the method (200) includes generating by, the control system (102), shot count, shot summary and machine cycle time based on the measured parameters of the die (D) and the die casting machine (M), wherein shot count indicates number of shots with respect to a time period, shot summary indicates summary of measured and evaluated parameters for selected shot(s), and machine cycle time indicates time period between each shot.
[0046] Further, the method (200) includes indicating by, one of a user interface unit (C, S) or an indicating means, the alerts and data received from the control system (102).
[0047] The technical advantages of the system (100) are as follows. The system improves product quality and operating condition of die(s). The system provides real time alerts to operator or supervisor or any other person on operation status of die and the die casting machine. The system enables precise controlling of duration of die spray (die lubricant) thereby improving product quality based on the operating temperature of the dies. The system reduces flashing in dies by monitoring and maintaining better thermal condition of die inserts. The system increases lifetime of die and also increases uptime of die. The system enables precise monitoring the temperature and pressure parameters die(s) and die casting machine(s) against predefined values and creating alerts in the event of violations thereby improving product quality. The system reduces percentage of rejection of the casting and down time of the die through timely alerts on its running status. The system enables easy and remote access to current production conditions of the die. The system maintains history of shot wise production data of all connected dies for assessing production performance, analysis and investigation, establishing relation between casting quality with production conditions.
[0048] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modifications within the spirit and scope of the embodiments as described herein.
,CLAIMS:We claim:
1. A system (100) for monitoring operating parameters of a die casting system, said system (100) comprising:
a control system (102); and
a die temperature sensing system (104) adapted to detect and communicate temperature of at least one die (D) to said control system (102),
wherein
said control system (102) compares the measured temperature of the at least one die (D) with predefined temperature value(s) and accordingly said control system (102) provide alert(s) if the measured temperature of the least one die (D) is not matching the predefined temperature value(s).

2. The system (100) as claimed in claim 1, wherein said system (100) comprises at least one first pressure sensor (106) adapted to detect and communicate pressure of oil in a cylinder (DSC) of at least one slider core (DS) of the die (D) to said control system (102),
wherein
said control system (102) evaluates oil pressure required for stripping of the at least one slider core (DS) of the die (D) based on the measured oil pressure in the cylinder (DSC) of the slider core (DS); and
said control system (102) compares the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) with predefined pressure value(s) and accordingly said control system (102) provides alert(s) if the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) is not matching the predefined pressure value(s).

3. The system (100) as claimed in claim 2, wherein said die temperature sensing system (104) comprises,
a first temperature sensor (104A) adapted to be connected to at least one moving insert (DM) of the die (D), said first temperature sensor (104A) adapted to detect and communicate temperature at the at least one moving insert (DM) of the die (D) to said control system (102); and
a second temperature sensor (104B) adapted to be connected to at least one fixed insert (DF) of the die (D), said second temperature sensor (104B) adapted to detect and communicate temperature at the at least one fixed insert (DF) of the die (D) to said control system (102),
wherein
said control system (102) compares the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) with corresponding predefined temperature value(s) and accordingly said control system (102) provide alert(s) if the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) is not matching corresponding predefined temperature value(s).

4. The system (100) as claimed in claim 3, wherein said system comprises a holding furnace temperature sensor (105) adapted to detect and communicate temperature of molten metal in a holding furnace (MF) to said control system (102),
wherein
said control system (102) compares the measured temperature of the molten metal in holding furnace (MF) with predefined temperature values and accordingly said control system (102) provides alert(s) if the measured temperature of the molten metal in holding furnace (MF) is not matching the predefined temperature value(s).

5. The system (100) as claimed in claim 4, wherein said system (100) comprises a accumulator pressure sensor (108) adapted to detect and communicate pressure of gas in at least one accumulator (MA) of a die casting machine (M) to said control system (102),
wherein
said control system (102) compares the measured gas pressure in the accumulator (MA) with predefined pressure value(s) and accordingly said control system (102) provide alert(s) if the measured gas pressure of the accumulator (MA) is not matching the predefined pressure value(s).

6. The system (100) as claimed in claim 5, wherein said system (100) comprises a intensifier pressure sensor (110) adapted to detect and communicate pressure of gas in at least one intensifier (MI) of the die casting machine (M) to said control system (102),
wherein
said control system (102) compares the measured gas pressure in the intensifier (MI) with predefined pressure value(s) and accordingly said control system provide alert(s) if the measured gas pressure of the intensifier (MI) is not matching the predefined pressure value(s).

7. The system (100) as claimed in claim 6, wherein said control system (102) is a cloud computing based control system which includes,
a controller unit provided in communication with said first temperature sensor (104A), said second temperature sensor (104B), said holding furnace temperature sensor (105), said first pressure sensor (106), said accumulator pressure sensor (108) and said intensifier pressure sensor (110) ;
a memory unit adapted to store data when internet connection is not available; and
a cloud system adapted to be provided in communication with said controller unit,
wherein
said controller unit of said control system (102) sends data to said cloud system; and
said cloud system compares the measured parameters of the die (D) and the die casting machine (M) with predefined values and accordingly said cloud system sends alert(s) to at least one user interface unit (S, C) or indicating means if the measured parameters of the die (D) and the die casting machine (M) is not matching the predefined value(s)
8. The system (100) as claimed in claim 1, wherein said control system (102) is a programmable control system which includes,
a controller unit provided in communication with said first temperature sensor (104A), said second temperature sensor (104B), said holding furnace temperature sensor (105), said first pressure sensor (106), said accumulator pressure sensor (108) and said intensifier pressure sensor (110); and
a memory unit adapted to store data;
wherein
said controller unit of said control system (102) compares the measured parameters of the die (D) and the die casting machine (M) with programmable values and accordingly said cloud system sends alert(s) to an indicating means if the measured parameters of the die (D) and the die casting machine (M) is not matching the programmable value(s); and
said indicating means adapted to indicate the alerts to the user based on input(s) received from the programmable control system (102).

9. The system (100) as claimed in claim 1, wherein said control system (102) is adapted to generate shot count, shot summary and machine cycle time based on the measured parameters of the die (D) and the die casting machine (M),
wherein,
said shot count indicates number of shots with respect to a time period;
said shot summary indicates summary of measured and evaluated parameters for selected shot(s); and
said machine cycle time indicates time period between each shot.

10. A method (200) for monitoring operating parameters of a die casting system, said method (200) comprising:
detecting and communicating by, a die temperature sensing system (104), temperature of at least one die (D) to a control system (102);
comparing by, the control system (102), the measured temperature of the at least one die (D) with predefined temperature value(s); and
alerting by, the control system (102) if the measured temperature of the least one die (D) is not matching the predefined temperature value(s).

11. The method (200) as claimed in claim 10, wherein said detecting and communicating by, the temperature sensing system (104), temperature of at least one die (D) to the control system (102) comprises,
detecting and communicating by, a first temperature sensor (104A), temperature of at least one moving insert (DM) of the die (D) to the control system (102);
detecting and communicating by, a second temperature sensor (104B), temperature of at least one fixed insert (DM) of the die (D) to the control system (102);
comparing by, the control system (102), the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) with corresponding predefined temperature value(s); and
alerting by, the control system (102) if the measured temperature at each of the moving insert (DM) and fixed insert (DF) of the die (D) is not matching corresponding predefined temperature value(s).

12. The method (200) as claimed in claim 10, wherein said method (200) comprises,
detecting and communicating by, a first pressure sensor (106), pressure of oil in a cylinder (DSC) of at least one slider core (DS) of the die (D) to the control system (102);
comparing by, the control system (102), the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) with predefined pressure value(s); and
alerting by, the control system (102) if the measured oil pressure in the cylinder (DSC) of the at least one slider core (DS) is not matching the predefined pressure value(s).

13. The method (200) as claimed in claim 10, wherein said method (200) comprises,
detecting and communicating by, a holding furnace temperature sensor (105), temperature of molten metal in a holding furnace (MF) to the control system (102);
comparing by, the control system (102), the measured temperature of the molten metal in holding furnace (MF) with predefined temperature values; and
alerting by, the control system (102) if the measured temperature of the molten metal in holding furnace (MF) is not matching the predefined temperature value(s).

14. The method (200) as claimed in claim 10, wherein said method (200) comprises,
detecting and communicating by, an accumulator pressure sensor (108), pressure of gas in at least one accumulator (MA) of a die casting machine (M) to the control system (102);
comparing by, the control system (102), the measured gas pressure in the accumulator (MA) with predefined pressure value(s); and
alerting by, the control system (102) if the measured gas pressure of the accumulator (MA) is not matching the predefined pressure value(s).

15. The method (200) as claimed in claim 10, wherein said method (200) comprises,
detecting and communicating by, an intensifier pressure sensor (110), pressure of gas in at least one intensifier (MI) of the die casting machine (M) to the control system (102);
comparing by, the control system (102), measured gas pressure in the intensifier (MI) with predefined pressure value(s); and
alerting by, the control system (102) if the measured gas pressure of the intensifier (MI) is not matching the predefined pressure value(s).

16. The method (200) as claimed in claim 10, wherein said method (200) comprises,
generating by, the control system (102), shot count, shot summary and machine cycle time based on the measured parameters of the die (D) and the die casting machine (M); and
indicating by, one of an user interface unit (C, S) or an indicating means, the alerts and data received from the control system (102),
wherein,
said shot count indicates number of shots with respect to a time period;
said shot summary indicates summary of measured and evaluated parameters for selected shot(s);
said machine cycle time indicates time period between each shot;
said control system (102) sends alert(s) to at least one user interface unit (S, C) or at least one indicating means if the measured parameters of the die (D) and the die casting machine (M) is not matching the predefined value(s);
said control system (102) is one of a cloud computing based control system or a programmable control system; and
said indicating means is one of a light, a buzzer and a display screen.