Turnkey Fully Automated Cells

Turnkey Fully Automated Cells

Key Benefits

Flexible automated solutions from simple to very complex configurations

Solutions tailored exactly to your needs

3D simulation of cycle times for the ultimate cycle time optimisation

In-house automation engineering

Key features

From simple to complex integration: we offer flexible, fully automated work cells for light alloy casting production that integrate peripheral devices, from the furnace to automatic deburring. No solution is too simple - we can engineer solutions from very simple configurations to very complex automated cells.

One comfortable supplier for the entire cell: Italpresse Gauss delivers turnkey solutions for a part or the entire cell and ensures efficient implementation. Our technology know-how and experience in the die casting industry means you can leave your project in our safe hands. 

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.

Applications

We engineer automated work cells for three die casting processes: high pressure die casting, gravity die casting and low pressure die casting. 

Automated light alloy casting cells are used in many industries from the most sophisticated sectors, such as automotive, to more standard applications, with castings ranging from lighting components to kitchen tools.

Our automated cells for automotive customers were designed for the production of engine blocks and mid to large light alloy parts, such as steering boxes, transmission cases, oil sumps, crankcases and clutch housings.

Modular and flexible

Our automated work cells are fully flexible. Their modular design allows major components to be configured to your specific needs.

Expert in-house automation engineering

We have been engineering automated solutions for aluminium foundries since 1975. Our teams of specialised engineers design the automation process of the cell to ensure the best cell configuration, and to achieve the best cycle time optimisation.

Quality cell = quality casting

Optimised and lean integration is key to ensuring a high quality of castings. Our technology know-how and in-house process optimisation enable us to design highly stable and efficient cells for the production of high quality light alloy castings. 

3D simulation for the ultimate cycle time optimisation

At your request, we can carry out 3D simulations to completely evaluate the project and provide an in-depth analysis of the cycle time. 3D simulations also help to ensure the cell operates in accordance with your production process requirements.

State-of-the-art hardware supported by advanced software

Our specialised software engineers support the project at every step of the cell implementation process, from the feasibility study to commisioning at your site; providing custom software, modifications, data storage and analysis, and offering the complete flexibility to ensure that all devices integrate as you want, and that the production cycle flows exactly as you need it to.

Operator-friendly

The control system is tailored to your needs. It is based on a standard Siemens or Allen Bradley PLC with software specifically designed for die casting. Its user-friendly design makes it easy to operate and upgrade as it is made of standard control components that offer reliability and availability of supply.

Supplied with HMe

All HPDC (high pressure die casting) machines are supplied with HMe, a machine control system with advanced data management and diagnostics capabilities. HMe offers real-time storage and powerful analysis of machine and process data, as well as the integration of peripheral and mobile devices. It opens up the possibility of controlling the whole die casting process holistically through a single user interface.

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Turnkey Fully Automated Cells Process

Solutions designed to suit you: click on the icon to discover more.

  HPDC (high pressure die casting)  GDC (gravity die casting) LPDC (low pressure die casting)
Furnace
Degassing


Automatic Core Assembly


Core Setting  

Insert Handling
 
Pouring

 
Vacuum


Extraction


Integrity Control Check


Lubrication / Talcing


Marking and Marking Check


Pre Decoring


Cooling (Air / Water)


Decoring  

Cutting


Deburring / Trimming / Handling


The following features are available as options:

AMe

A powerful app for live remote maintenance and service assistance. The augmented reality AMe app enables you to trouble-shoot via a live video connection with an Italpresse Gauss expert. It also enables you to access drawings and machine documentation and to follow maintenance guides on screen – all via a tablet, it's so easy to use.

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ECO-FIT and ECO-FIT PLUS

Achieve energy savings of up to 50% with our energy efficient ECO-FIT solutions. ECO-FIT and ECO-FIT Plus can be integrated into the HPDC and GDC machines to regulate the hydraulic pumps to reduce energy consumption, reduce hydraulic fluid temperatures and reduce noise levels. Both solutions deliver instant benefits. In addition to lower energy consumption, they also include a reduction of the hydraulic fluid temperature and a lower noise level. Both ECO-FIT Mode and ECO-FIT Plus can be retrofitted on existing machines.

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