Gravity Die Casting Flexible Cell

Gravity Die Casting Flexible Cell

Key Benefits

Low and medium volume production

Maximum flexibility in production change

Flexibility in the choice of typology and automation for the machine

Sophisticated supervision system to guarantee the highest casting quality

Key features

  • Ideal for low and medium volume production
  • From 1 to 2 gravity die casting machines
  • Offers maximum flexibility in production change
  • Offers “investment modularity” - when your production volume changes, you can easily add more gravity die casting machines onto the flexible cell, spreading your investment cost

Contact us today to discuss your production needs.

Applications

Gravity die casting machines are ideal for diverse complex aluminium casting production of automotive parts such as: turbos, brake calipers, knuckles, engine cylinder heads, engine blocks and pistons. It suits many other industries too, from lighting components to kitchen tools.

Engineered by experts to deliver:

  • Very high production rate and better resource control (labour, energy, costs)
  • Absolute flexibility with the installation of any type of gravity die casting machine
  • Tailored solutions to suit your exact needs: we work with you to create the perfect layout for the reliable integration of an automated working cycle
  • Full automation with Gauss gantry or with anthropomorphic robots of the most requested brands with the following functions: core setting, pouring, unloading, pieces marking, pre-decoring and filters placement

Our gravity die casting (GDC) machines which can be built into the cell include:

  • Die horizontal opening machines
  • Die vertical opening machines
  • 0/90° tilting machine controlled by hydraulic servo-valve, GT CAST-ID series
  • 0/120° tilting machine controlled by servomotor, GT CAST-EL series

Quality casting, every time

Our automated GDC solutions are engineered with a sophisticated supervision system to guarantee the highest casting quality. The supervision system offers: 
  • Traceability of produced pieces
  • Storage of all dies and furnace temperature parameters
  • Control of die heating/cooling and the respective storage of the temperature curves
  • Programming and control of all system function parameters
  • Setting up of specific “receipt” with storage of all the parameters
  • Connection with production management system and customer data centralisation

We offer expert automation engineering of the following die casting processes:

Cores preparation 

Various devices and solutions for the preparation, transport and storage of sand cores that will serve the casting line. Each device is supplied with static or dynamic fixtures and auxiliary equipment designed according to the type of sand core.

Core setting

In order to automate the operations of inserting the cores into the dies of the gravity casting machines we use Gauss portal system or anthropomorphic robots of major brands. Each device is equipped with a special gripper specifically designed for the type of cores to be transported.

Pouring

In order to automate the operations of picking and carrying molten light alloy, from melting and holding furnaces, to pouring into the dies of the gravity die casting machines, we use customized Gauss system or anthropomorphic robots of major brands. Each pouring robot can be combined with one of the casting arms, single ladle or multiple ladles, designed and guaranteed by Gauss' experience and expertise. The pouring robots can be supplied with ancillary devices such as degassing units, ladle cleaning stations and ladle preheating devices.

Extraction

In order to automate extraction process of the cast part from the gravity die casting machines we use Gauss portal system or anthropomorphic robots of major brands. Each device is equipped with a special gripper specifically designed for the type of cores to be transported.

Options that can be integrated into the gravity die casting automation:

  • Die change device: Various auxiliary devices to improve die change operations
  • Cooling: Several solutions to cool the parts after the casting process
  • Marking Micropercussion or Datamatrix: Marking devices for Alphanumeric or Datamatrix codes
  • Pre-decoring: Two different solutions for breaking sand cores before loading castings into cooling devices
  • Flash trimming: Automatic solution and peripheral devices for removal of risers and sprues
  • Conveyor device to transport the cast part
  • Automatic degassing system
  • Smoke suction hoods

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