Professional Documents
Culture Documents
We thank you for your kind request and we have pleasure in sending you our offer for the
supply of:
Pos. Description
1. Price details
1.a Basic machine configuration and standard equipment
1.b Auxiliary and/or requested machine equipment
1.c Peripheral equipment
2. Supply conditions
3. General sales conditions
4.a Technical machine description
4.b Machine optional description
4.c Peripheral equipment description
1. PRICE DETAILS
Clamping Unit:
o Automatic point-to point oil toggle lubrication
o Block-Control "I" (control and automatic adjustment of clamping force)
o Adjustable sliding shoes on moving platen
o Die height adjustment with hydraulic motor
Safeties:
o die safety (final close in very low pressure)
o die filling check (injection piston stop at 2nd phase start point)
o electrical safety guard on operator’s side (fixed to the floor)
o electrical safety guard on operator’s opposite side (fixed to the floor)
o accident coverage for all moving parts
o protection guards (manually operated) on both injection sides
o electro-hydraulic safety on closing/opening
Paint:
o Machine colour GREY RAL 7035
o Safety guards colour BLUE RAL 5014
Documentation:
o No. 1 set of machine operating and maintaining manuals (paper copy)
o No. 1 copy of machine operating and maintenance manuals on CD-ROM
(available languages : Italian, English, German, French, Spanish. Other languages
on request)
o CE Certificate type A for the machine only according to the current rule 2006/42/CE
NOTE:
The supply does not include:
2 Electric Interfaces:
2.01 Electric interface for Vacuum System € 1.130,00
7 Miscellaneous:
7.04 Box with flowmeters and thermometers with 8 circuits fitted on € 2.700,00
operator side (without piping)
7.13 Anti-vibration pads € 13.830,00
7.14 Feeding system on pump motor by means of vector inverter for energy € 23.030,00
saving
7.18 Thermoregulation unit plant on the machine, 4 circuits on moving € 38.500,00
platen and 4 circuits on fixed platen , consisting of:
-Modular ducts containers, containing stainless steel pipes AISI 316
with insulation by glass wool and with hydraulic joints at the endings;
- Manifolds complete of stainless steel taps 1/2" and hydraulic links for
connection to the hoses;
- Stirrups of anchorage
- 3/4" stainless steel hoses from the thermoregulators to the fixed
installation and from the fixed installation to the manifolds of the fixed
and mobile part of the die with translation;
- Docking station, 4 positions (4 units double zone)
5.01 1 Adaptive System with Inverter on the pump (IECI Patent) driven € 5.800,00
by the differential of temperature (price for 4 units).
5.02 1 Full software connection system by Gateway Modbus/Devicenet € 1.100,00
towards DCM IDRA
Note:
Quotation for special delivery conditions is available on request
See point 1.g “Services”
Where despatch and/or delivery of the goods are prevented or delayed through
Force Majeure, due to unavoidable or unforeseeable circumstances which are
beyond of the control of Idra, such as strike action, or their suppliers’ or
carriers’ companies, accidents, administrative or regulation-related difficulties
etc. Idra cannot be considered liable.
Packing: Excluded.
Quotation for packing is available on request, such as:
- Protection grease for sea fright
- “Open Top” container or wooden crates
Delivery terms: The terms are as machine tested and ready for customer’s approval at our
works.
It is 8 months from:
a) Date of receipt written Purchase Order complete with technical specification
b) Full respect of payment terms (as explained in the clause “Payment
Terms”)
c) If anything different is not requested or not indicated in your purchase
order, we will follow the standard configuration shown in our offer.
d) The delivery date valid for contract terms is the one indicated in our order
confirmation.
e) Any modification and/or addition during manufacturing period can cause
delivery delay and/or extra costs.
Any payment delay, not in compliance with the terms of payment indicated in
the order confirmation, will be charged a late payment interest rate applicable
under the Italian Law and calculated for the entire period of the delay.
The parties agree that, in case of default or breach of the payment terms, any
penalty clause at IDRA’s charge included in customer’s order will no longer be
enforceable.
Reserve on property: Idra is entitled to retain ownership of the supplied equipment until full and final
payment of the invoiced price is made.
Supply limits: This offer includes only the items stated and listed; therefore everything not
mentioned is excluded.
We point out following exclusions:
- Foundations and all civil building work;
- Internal transportation and handling an customer’s works;
- Air, water and electrical connections to customer’s network;
- Interface connection between supplied equipment not provided by Idra;
- Hardware and Software modifications and/or updating of customers’
equipment.
NOTE: Machine acceptance is mandatory before the cell can be used for
commercial production.
For proper installation and start-up, the Customer is responsible for the
following activities:
- Prearrangement and installation for water – compressed air – gas.
- Prearrangement and installation of all cables, cable ducts, underground
passages for feeding and connection of the control cabinets of all the
equipment specified in the P.O.
- All necessary foundation preparations indicated in the Foundation
Drawing attached to the P.O.
- All lifting means, crane, etc. are at customer’s care and cost.
- Technical personnel to support our technicians on site (mechanical,
electric and hydraulic), local transport, Hotel and meals, visa, etc. and
if necessary a translator.
- Safety fencing and doors around the equipment, which are not supplied
by us.
- Make available personnel for training provided by IDRA, to IDRA’s
schedule, for interface, safety and maintenance.
IDRA will, at its discretion, repair or replace such components, which prove to
be defective during the warranty period. However the defective part must be
returned to IDRA works.
Wearing parts, consumables, and parts in contact with molten aluminium are
excluded from the warranty.
We are with pleasure at your complete disposal for any further information you may need
and remain
Yours faithfully
IDRA S.r.l.
_______________________________
The “OL-CS” range of cold chamber pressure die casting machines are designed and
manufactured according to IDRA experience and customer’s inputs, for high
performance and constant product quality in time.
CLOSING UNIT
The mechanical structure of the OL-CS range machines is the outcome of long
technological experience with continuous improvement to the solutions used, which
guarantee long duration and higher performance.
Bushings and pins are made in steel and have a point-to-point oil lubrication system
fed by a centralized controlled unit with a safety pressure switch.
Moving platen and connecting rods are made from widely dimensioned castings to
ensure maximum stiffness. Movement is extremely smooth due to adjustable bronze
sliding shoes which slide on hardened and tempered guides fitted on the machine base.
Moving platen stroke can be set by transducer and controlled by proportional valves.
Platen parallelism is fast and simple by adjusting the tie bar nuts of the fixed
platen.
Fixed platen designed for limited bending and excellent support for dies and with
water cooling circuit.
Central ejection unit consists of a thick plate operated by 2 hydraulic cylinders for
free stroke adjustment by the stroke transducers.
Forward and return movements controlled by adjustable timers with independent
setting of speed and pressure and possibility of repeatability.
Machine tie bars in hardened and tempered steel alloy Ni-Cr-Mo with hard chrome
plating for high resistance to wear and corrosion. Tie bar locking with special traction
nuts on fixed and cylinder plates. The thread is obtained by cold rolling which ensures
better resistance compared to the turned threads.
Unit for measuring and monitoring the locking force. The set tolerance load of each
tie-bar is controlled by means of special electronic transducers, which send a signal to
the terminal. In case the clamping force is not within the set range, it automatically
provides to take it to the correct value
The machine base has a electric welded steel structure and is very rigid to guarantee
machine alignment and distribution of loads.
INJECTION UNIT
The injection unit is in integrated and modular hydraulic steel blocks which avoid
use of external pipes thus reducing the risk of oil leaks. Lifting for injection position
adjustable by means of a hydraulic cylinder. Hard chromed injection cylinder with a
one-piece injection piston and glide rings and pressure seals.
Speed adjustment of the injection phases is by means of proportional valve which
controls the flow on the cylinder discharge to enable final braking..
Third phase intensification is by means of a separate intensification cylinder with
control of the final pressure value with back pressure control by the Idra Bicostant
system assuring a reliable constant final value and reducing pressure peaks due to
intensification high speeds.
Intensification plunger movement is displayed on an external rod.
The hydraulic unit of the OL CS range machines is made exclusively with components
from international high qualified vendors. Maximum hydraulic line pressure 160 bar.
The unit has a large capacity tank incorporated in the machine base with an electric
level control and filtering system. Hydraulic proportional valves situated on manifold
with cartridge valves control all movement flows and pressures..
High pressure flexible hoses are used to minimize rigid pipes. The unit is equipped
with exclusion valves to simplify hydraulic fault finding.
The hydraulic circuit with proportional valves enables the following parameters to be
set:
Flows Pressures
Die mounting Die mounting
Slow-fast die closing Low pressure
Die safety High pressure
Final closing flow Slow closing
Slow opening Closing final pressure
Fast opening Slow opening
Opening brake Opening brake
Central ejection forward-back Central ejection forward
Fast-slow die height adjustment Die height adjustment
Core pulls IN-OUT Biconstant charge (intensified pressure)
Closed loop injection with 10 speed steps
(1st and 2nd phase)
2nd injection phase (fast shot)
3rd injection phase (intensification)
Biscuit ejection
Injection plunger return
Min.-max. flow
The electric system on the machine is wired with armoured metal sheaths and fireproof
cables. The electric control is positioned in a separate control panel. The electric unit
conforms to the CEI, VDE, IEC safety standards.
The system is configured in a new touch rich environment with about 90 pages
depending on cell configuration, using tablet style gestures for navigation. The
industrial PC is equipped with Intel i7 latest generation CPU and Windows 7
embedded x64.
Hard disk are SSD military grade.
Operator interface with 18.5” multi touch industrial display(1366x768) and additional
keyboard with the following functions:
- interactive 3D synoptic with “Help” manual and corrective actions
- simplified graphical setting of parameters and optional functions.
- diagnostics and alarms with help functions for fault finding, storage of data
and statistical analysis with graphic visualization of injection curves
Peripherals such as : extracting Robot , Die Lubricators, Trimming Presses and Die
Thermoregulating Units are connected in Profibus or Profinet and are completely
integrated in to the supervision system with alarms which are available and
presented in the same ways as DCM alarms complete with history, so that trouble
shooting and production re-start are simplified.
Machine programme is recalled from die data files and programmes for peripheral
operation are automatically activated.
Numerical control of all process parameters with the possibility to set tolerance
values and to use the parameters to output signal for casting quality and control.
Production control managed from MS SQL Server with the possibility to be integrated
into the company foundry management system.
Voltage control for 24V inputs and outputs with I/O cards on machine (Profinet).
All machine movements, core pulls and central ejection are according to the selected
program and fully protected by interlocks.
Automatic toggle lubrication, oil type point to point with pump-tank group, electric
level control and pressure switch to control the lubrication cycle. The operator can
adjust intervals and duration.
4.1.5 PRE-ARRANGMENTS
The pressure die casting machine is equipped with the following electric and hydraulic-
mechanic pre-arrangements:
The 3-phase injection system of the OL CS series machines has a pressure intensifier
with separate control circuit. Intensification plunger is monobloc, positioned in line
with the injection cylinder, is connected to a rod that displays the movement.
Independent flow control of the 3 injection phases with proportional valves for fast
reaction times and consistent repeatability.
The injection cylinder diameter is sized to guarantee an adequate injection force even
with castings of reduced thickness and dry shot speeds higher than 7.5 m/s.
With the ICS II system, IDRA Control System II for the closed loop control of
injection , (supplied as an option), adjustment of the injection parameters is in real
time. This system gives the following advantages:
BICONSTANT
The Patented Biconstant system controls the final pressure value (intensification).
It consists of an oil-nitrogen accumulator, which adjusts the intensification cylinder
backpressure by absorbing the pressure peaks associated with intensification high
speeds. The system guarantees repeatability of the final pressure value and dry
intensification times lower than 15 milliseconds.
DESCRIPTION
PROGRAM 1 PROGRAM 2
(without core pulls) (with core pull group 1 on movable plate)
When extra hydraulic control valves are fitted, the following programs are also
available (see optional equipment for additional cost).
PROGRAM 3 PROGRAM 4
(with core pull group 3 on fixed plate) (with core pull group 1 on movable plate)
(with core pull group 3 on fixed plate)
PROGRAM 5 PROGRAM 6
(with core pull group 1 on movable plate) (with core pull group 1 on movable plate)
(with core pull group 2 on movable plate) (with core pull group 2 on movable plate)
(with core pull group 3 on fixed plate)
- No. 1 paper copy and No. 1 electronic copy of the machine Use and Maintenance
Manual. Available languages: Italian, English, German, French. When placing
order and at an additional price, other languages can be requested.
-
- No. 1 set of special spanners
- Machine colour Grey (RAL 7035) – safety guards colour Blue (RAL 5014)
- standard cable length between control panel and the derivation box positioned on
the rear side of the machine is 7mt. (different cable lengths can be supplied but
must be defined at order)
► CE Certificate type A for the machine only according to the current rule
2006/42/EC
► The main safety protection and prevention devices installed on the machine are:
1.02 S.P.C Statistical data analysis with management of the production Database
For online statistics analysis of the control parameters, to display the control cards
(X-R chart) and for automatic calculation of the statistic indicators.
Software and communication card to display the machine state on PC with remote
control connected to the machine panel through the network.
A nozzle lubricates the injection plunger head. Lubrication frequency and spraying
flow are set on the panel. The device complete with pressure tank, is according to
ISPESL and TUV standards
Hydraulic and electric device for control of an additional group of core pulls
located on the movable plate and independently activated from the other core pull
groups. (Valve size to be agreed at order).
Hydraulic and electric device for control of an additional group of core pulls
located on the fixed plate and independently activated from the other core pull
groups. (Valve size to be agreed at order).
Manual pressure reducer complete with tap and pressure gauge for control of one
core pull group.
Hydraulic mechanism for unlocking the nut and two hydraulic cylinders for
withdraw of the tie bar. Activated by switches on the push button panel for quick
change of large dies.
Unit for measuring and monitoring the locking force. The set tolerance load of each
tie-bar is controlled by means of special electronic transducers, which send a signal
to the Metrel. In case the clamping force is not within the set range, it
automatically provides to take it to the correct value
Hydraulically operated automatic die clamping acting on pins fixed to the rear plate
of the die.
Automatic central ejection device for rapid clamping to the die ejection plate with
bars that clamp the plugs tongs.
Operation
Example:
Tap is for de-pressurizing the line from the system at the first intercept valve on the lubricator,
naturally when tap is open.
Pressure gauges control : line pressure , pump suction pressure, pumping pressure and pressure sent
to the lubricator.
Taps are for optimizing the suction pipe direction of the release agent.
With a kit available on request it is possible to carry out a quick change of the release agent, as long
as it is compatible with the previous type used, without having to replace the sleeves and with less
waste of product.
The flow-stop valve stops eventual returns of water-release agent mixture into the line.
An electric cable is connected to the electric box for level control of the release agent.
Depending on the users needs the pumping system can be located either on the floor or lifted by the
supports provided.
The F ( Foundry Plus ) model has been designed for applications in particularly "hostile" place,
such as the foundry .
Its main characteristics are: the special surface treatment , the IP67 protection in robot body , and
the control panel cooling, that guarantee the proper functioning in ambient temperatures up to 52 ° .
The robot function is to carry out the unloading of the pressure diecasting machine, interlocking of
the relative trimming press, after casting control presence by photocells and cooling, and die
lubrication..
Westomat® is a holding furnace without crucible, equipped with heating system by silicon
carbide resistances electronic system for molten metal dosing, both combined in a single
operation unit.
Dosing of the liquid aluminium is made by a delivery pipe immersed in the load by air
overpressure in the furnace closed opening. Progress of overpressure is controlled by
software so that counterpressure is done when the set dosing quantity is reached.
Introduction of dosing quantity is freely managed by the user from the control input menu.
The furnace basin is made in high quality ceramics, resistant to aluminium and to the
aggressive refining agents.
DOSING UNIT FOR ALUMINIUM TYPE WESTOMAT 2300 S ProDos 3, complete with:
Resistance-heated holding furnace (incl. special drying)
- one set of electric resistance heating elements (3 pcs.)
- duplex thermocouple for metal
- SiC-thermocouple protective tube
- Thermocouple for furnace chamber
- Filling funnel
Dosing system
- one riser tube (complete)
Control panel
- dosing control ProDos® 3
- temperature controller – metal / furnace chamber and heat input control
- signal interface to the pressure diecasting machine
- molten metal under and over temperature controller
Lifting/tilting device (shears table)
- With hydraulic cylinder and hand-operated pump
U.M. W 2300 S
Capacity Kg (Al) 2300
Working capacity Kg (Al) 1800
Connecting capacity kW 36
Noise level dB 78
Furnace dimensions:
Width mm 2260
Length mm 3650
Max. Height (with scaffolding) mm 3290
Furnace weight (with scaffolding) Kg 7050
Control cabinet dimensions:
Width mm 400
Length mm 800
Max. Height mm 1900
Weight Kg 200
A = Indicatore di livello
B = Incastellatura di sollevamento ed inclinazione G = Allacciamento pneumatico
C = Termolelemento (vano forno) H = Allacciamento elettrico
D = Sportello di pulizia I = Pompa a mano
E = Sfiato di emergenza forno L = Coda a strappo (tramoggia di riempimento)
F = Cella di pesatura carica (opzionale) K = Arresto