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Die Casting Machinery Rebuilding and Remanufacturing
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Hydracast has been involved in the manufacturing and remanufacturing of die casting machinery since its inception. The company was organized in 1992 to meet the demands of die casters for a source with the experience and capabilities to upgrade and modernize their die casting equipment.
Assembling skilled personnel with backgrounds in die casting machinery was the highest priority. Drawing from this group we have assembled a team capable of taking a machine from total disrepair to like new condition.
Having acquired the proprietary engineering files of a leading manufacturer of die casting machinery, we were able to offer our customer base assurance that their machines would be built to standards the same or better then the original.
Additionally, we have developed the latest state of the art engineering in controls and hydraulics to offer the customer the opportunity of upgrading their older machines to newer technology.
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We have the facilities to do everything from simple mechanical toggle rebuilding to complete machine overhauls including mechanical, hydraulic, controls, furnace and safety. All of our work is warrantied against defects in workmanship and parts for one year. Additionally, we can offer a stock of standard spare parts to service machines in the field assuring backup after rebuilding. |
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Controls
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We have developed proprietary circuitry for control systems for die casting machines. We use Allen Bradley SLC500 series programmable logic controllers coupled with touch screen operator interfaces which allow unlimited versatility and enable us to custom tailor the machine controls to the customer’s specific applications.
All of our controls feature the ability to run machines for setup, single cycle or fully automatic cycle. Additionally, functions for spray systems, core pulls, ejection, conveyors, burner and temperature controls are also incorporated into the circuits.
Our unique machine monitoring and trouble shooting circuits allow observation of the equipment while it is running. Icons and alarm messages are displayed on the interface screens and live action images show status of everything from machine operation mode to individual inputs and outputs of the processor. The actual circuit is displayed on a screen and settings for timers, counters, cores, spray and temperature as well as production counts and cycle time can be accessed in real time.
Special features such as supervisor codes for limiting access to screen operations, dual language capabilities and die memory with alpha numeric log on screen are also available. All rewiring work is done in new enclosures with all new wiring and terminals. All external wiring to machine inputs and outputs is also replaced with new wiring and special wire number markers impervious to oil and temperature.
We have provided new controls for hot and cold chamber conventional machines and we have also developed a special control system for four slide die casting machines such as Dynacast and Techmire. We have sold stand alone control systems for customers to retrofit to existing machines.
These are examples of different controls we have furnished on a variety of machines we have rebuilt.
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Mechanical rebuilding consists of the complete overhauling of the platen and toggle mechanism of the die casting machine. This includes grinding of the tee slotted surfaces of the front and moving platen; replacement of all toggle links, toggle pins and bushings; replacement where necessary of the toggle ears, crosshead, tie bars and nuts; repair or replacement of the cylinder mounting and knockout plates and addition or restoration of ratchet safety devices and hydraulic ejection cylinders. The resulting work makes the machine platen and toggle system as good as new. This service can be performed on machines in the field where only the mechanical system must be rebuilt. |
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Hydraulics on machines can be restored to original specifications or modernized to the latest technology. We can maintain the original circuitry while replacing old solenoid and pressure valves, cylinders, motors, pumps, filters, accumulators and heat exchangers. We can also upgrade older systems to provide higher performance including larger motors and higher capacity pumps, larger valves and shot lines and cartridge valve technology enabling faster operation with higher shot end performance.
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Furnaces and burner systems can be upgraded including packaged systems supplied by PowerFlame with enclosed burners and Honeywell controls. We rebuild the entire furnace shell with new heavier material and line the furnace wall with high heat resistant castable refractory material. Temperature controls can be incorporated into the machine PLC or supplied as stand alone at the customer’s preference. All work is done with the idea of maintaining standard shot end parts such as goosenecks, pots and burners for future maintainance.
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Safety systems required by local and national standards can be incorporated in all of or rebuilds. We can upgrade circuitry, machine guards, redundant interlock switches, ratchet safety systems and signage on an existing machine. All machines we rebuild are furnished with this equipment as standard. Circuitry provided with a PLC enables us to insure that unauthorized modifications will not create unsafe operating conditions and all rebuilds carry signs addressing this situation.
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Our goal is to provide a rebuilt machine which is capable of giving the customer years of trouble free use. We do this at a fraction of the cost of a new machine. We have many satisfied customers that we have done repeat work for which is our best selling point.
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