How To Train A Die Casting Machine

Transcription

1 Bühler Training. Program Overview Die Casting.

2 The Bühler trainer competence impressed me as a course participant. I could quickly and profitably implement my new knowledge at my company and that is motivating!

3 Your success in the spotlight. Comprehensive know-how in the die casting process. Having a well-educated staff is a key factor for die casting. Increasing requirements made of die cast components and their use in demanding areas of application require sound knowledge of the production process. Bühler has comprehensive experience with the entire die casting process: from the basics of die casting to the operation and maintenance of our machines. With our expert knowledge of the most varied technologies, we are in a position to answer any questions you might have. Your success is central to our training courses. We enable you to increase your productivity while manufacturing parts of the highest quality. This can permanently enhance the profitability of your company in the long-term. Grasping and understanding with practice Basic conditions that allow you to focus fully on the course are essential to the successful completion of the training. This is precisely what we can offer you at our tech center in Switzerland. Equipped with four die casting machines, peripheral equipment and a lab, the center offers course participants practical knowledge of die casting. Our instructors have comprehensive experience with foundries and impart this knowledge expertly and passionately. More than 70% of the training courses in Europe are offered at our facilities. We can also provide training at your facilities upon request. BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING 3

4 Practical at international locations. Very close by. We offer training courses both at our headquarters in Uzwil, Switzerland and also around the world. This allows us to be close to you: we can also provide training at your facilities as needed. Please ask us for a proposal that would be tailored to your needs. The courses we offer on the subjects of Operation & Programming and the courses on Service & Maintenance are tailored to our three die casting machine models: Carat, Evolution, Ecoline and Ecoline(Pro). By contrast, courses in technology are set up to be independent of particular machines. Using the Bühler simulator, participants are able to learn through realistic but safe experiences how to work competently with die casting machines. Our current die casting machines operate with the Datanet control system. As needed, we also offer training courses on the functionality of older generations of control systems, e.g. Dataspeed. We conduct additional trainings for advanced participants upon request. Your competent trainer team. 4 BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING

5 HOLLAND, MI/USA T dc.training-usa@buhlergroup.com UZWIL/SWITZERLAND T dc.training@buhlergroup.com WUXI/CHINA T dc.training-china@buhlergroup.com BANGALORE/INDIA T dc.training-india@buhlergroup.com Overview of Training Courses Technology Operation and Programming Maintenance Work Process Optimization Die Design Setting up Carat & Evolution Carat Hydraulic System Evolution Hydraulic System Carat Electronic System Evolution Electronic System CARAT EVOLUTION Casting Errors Setting up Ecoline(Pro) Ecoline(Pro) Hydraulic & Electronic Systems ECOLINE(PRO) Basics of Die Casting Programming Robots BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING 5

6 Technology. s of the trainings. PROCESS OPTIMIZATION With specialized knowledge in the area of process optimization, the participants will shorten cycle times, improve the quality of components and increase the productivity of the die casting cell. In addition, dies will have a longer service life if they are handled professionally. All of this will have a direct influence on the economic success of a foundry. Basics of metallurgy Process monitoring Analysis of casting parameters How to recognize process errors and their causes Process optimization (quality / cycle time) How to protect the die during casting How to recognize statistical correlations Systematics of spraying technology and die tempering Casting trials Target group: technologists, fitters, purchasing agents, quality specialists Pre-requisites: an understanding of casting technology Duration: 4 days 6 BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING

7 DIE DESIGN With intelligent gating systems, optimal ventilation systems and a well-conceived die tempering system, you will increase the quality of the components and reduce cycle time. This will also allow for the production of more complex components. This knowledge will make it possible to implement state-of-the-art technology in engineering. Furthermore, you will save time and money through shorter optimization phases and fewer tool modifications. Basics of die casting technology Basics of flow technology Construction and design of dies Analysis of simulations Die concepts Gating technology and calculations Die ventilation and over flowing Runners Die tempering (design and calculation) Target group: Die design engineers, technologists Pre-requisites: an understanding of casting technology Duration: 4 days CASTING ERRORS (Causes and Remedies) The participants will learn to recognize deviations in quality early and to intervene in the manufacturing process purposefully: this is how the number of rejects can be reduced and productivity increased. The knowledge gained from the training course will also help participants to counter potential casting errors already in the product development and tool design stages. The 20 most common casting errors in die casting Cause and effect Systematics and ramifications How to prevent casting errors Hands-on training Target group: engineers, technologists, casting and quality specialists Duration: 2½ days BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING 7

8 Operation and Programming. s of the trainings. SETTING UP CARAT & EVOLUTION Efficient production can be achieved by taking full advantage of the functional and technological potential of the die casting machine. In addition, competent diagnosis of malfunctions leads to shorter down- times and therefore, higher availability of the system. Participants will learn how to operate and program the Bühler Carat und Evolution die casting machines as well as peripheral equipment independently and will gain valuable knowhow for preventative maintenance. Structure and function of die casting machines & safety Machine and system operation Programming and settings for the DCM & die Programming the equipment and vacuum technology Practical casting trials Process monitoring Diagnostic analysis of the casting process Identifying simple malfunctions of the process or machines Target Group: Setters, machine operators, adjusters, technologists Duration: 4 days 8 BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING

9 SETTING UP ECOLINE(PRO) Efficient production can be achieved by taking full advantage of the functional and technological potential of the die casting machine. In addition, knowledge of the basics of the die casting process leads to competent diagnosis of malfunctions and to shorter downtime and, therefore, greater availability of the system. Participants will learn how to operate and program the Bühler Ecoline die casting machine independently and how to select peripheral equipment. They will also gain insight into preventative maintenance of the equipment. Basics of die casting Structure and function of die casting machines & safety Machine and system operation Programming and settings for the DCM & die Practical casting trials Process monitoring Diagnostic analysis of the casting process Identifying simple malfunctions of the process or machines Target Group: Setters, machine operators, adjusters, technologists Duration: 3 days PROGRAMMING ROBOTS (ABB IRC5 oder Kuka KRC4) Participants will learn how to program the robot independently to ensure that they can carry out retrofitting procedures without requiring any external help. The goal of the training course is to ensure that participants will be able to use the integrated robot (BuhlRob) efficiently and safely, and that measures required to optimize the process (see training course Process Optimization ) can be implemented in the foundry without delay. Settings for the HMI of the DCM for BuhlRob How to load all Bühler-specific program modules and configuration files Teaching a complete cycle and test run on the system using a simulated DCM How to develop additional programs for additional components Trouble-shooting / error handling / safety settings on BuhlRob Target group: Setters, process engineers, process optimizers Pre-requisites: Basics of robot manufacturing Duration: 2 3 days, training upon request BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING 9

10 Maintenance Work. s of the trainings. CARAT HYDRAULIC SYSTEM In this course, participants learn how to identify malfunctions of the hydraulic system of the Bühler Carat die casting machine faster and how to use their detailed knowledge to remedy them more effectively. Participants will also be informed about preventative maintenance, so that they are able to reduce unscheduled downtime and to extend the service life of the machines. In addition, when you increase the availability of your plant, you increase the competitiveness of your foundry. EVOLUTION HYDRAULIC SYSTEM Basics of hydraulics Structure and function of hydraulic systems of die casting machines Details about hydraulic components (pumps, valves, proportional hydraulics) Operating and programming Bühler s Carat die casting machine Fault analysis and resources How to trouble-shoot Practical trouble-shooting on die casting equipment Safety equipment Maintenance and service for hydraulic systems Same as the Carat hydraulic system. Target Group: Metal workers, maintenance specialists Duration: 4 days 10 BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING

11 CARAT ELECTRONIC SYSTEM In this training course, participants learn how to identify malfunctions of the electronics of the Bühler Carat die casting machine faster and to use their detailed knowledge to fix them more effectively. Participants will also be informed about preventative maintenance with which they will be able to reduce unscheduled downtime and to extend the service life of the machines. In addition, when you increase the availability of your plant, you increase the competitiveness of your foundry. EVOLUTION ELECTRONIC SYSTEM Same as the Carat electronic system. Operating and programming Bühler s Carat die casting machine Structure and function of the electric and electronic systems of die casting machines Control technology Feedback control technology of the proportional hydraulic system Electrical safety gates Machine sensor technology Interfaces Fault analysis and resources How to trouble shoot Practical trouble-shooting for die casting systems Target group: Electricians, automation specialists, mechatronics engineers Duration: 4 Days ECOLINE(PRO) HYDRAULIC & ELECTRONIC SYSTEMS In this training course, participants learn how to identify malfunctions of the hydraulic and electronic systems of the Bühler Ecoline(Pro) die casting machine faster and to use their detailed knowledge to fix them more effectively. Participants will also be informed about preventative maintenance with which they will be able to reduce unscheduled downtime and to extend the service life of the machines. Operating and programming Bühler s Ecoline(Pro) die casting machine Structure and function of the electric and electronic systems of die casting machines Control technology Control feedback technology of the proportional hydraulic system Electrical safety gates Machine sensor technology Interfaces Fault analysis and resources How to trouble shoot Practical trouble-shooting for die casting systems Target group: metal workers, maintenance specialists, electricians, automation specialists, mechatronics engineers Pre-requisites: Knowledge of hydraulics and electronics Duration: 4 days BÜHLER TRAINING PROGRAM OVERVIEW DIE CASTING 11

12 DC en gl Bühler AG CH-9240 Uzwil, Switzerland T F die-casting@buhlergroup.com www buhlergroup.com/die-casting