VACUUM FOR HIGHER QUALITY. In pressure die casting

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1 VACUUM FOR HIGHER QUALITY In pressure die casting

2 A FASCINATION FOR VACUUM Pioneering spirit Founded in 1946 in Switzerland, Fondarex is the inventor of the vacuum technology for pressure die casting and plastic injection molding. As international market leader in these two fields, Fondarex continues to invest in research and development and is committed to meeting the demands of current technology and market requirements. The Fondarex team works to ensure its customers success, by guaranteeing the production of cost-effective, high quality parts with its vacuum systems. Offering customized consulting, training for users and technical support, Fondarex is your partner for the future. History A rise to the top 1946 Fondarex is set up as a pressure die casting foundry by Mr. Fritz Hodler, in Montreux 1952 Invention of the first vacuum system for the pressure die casting industry 1989 Fondarex is taken over by Mr. Konrad Baumgartner 2002 Launch of the first vacuum system for the plastic injection molding industry 2010 Launch of the ECONOMY 1C, and vacuum systems 2012 Launch of the ULTIMATE 4C vacuum system and the EXVAC shot sleeve air evacuation system CONTENT 2016 Launch of the HUMIDITY SENSOR, the advanced vacuum unit and the pump management system COMPANY PIONEERING SPIRIT / HISTORY 3 TECHNOLOGY OUR PRINCIPLE / RESEARCH & DEVELOPMENT 6-7 OUR PERFORMANCES / YOUR ADVANTAGES 8-9 PRODUCTS VACUUM SYSTEMS HUMIDITY SENSOR VACUUM VALVES CHILL-BLOCKS SERVICES VACUUM APPLICATION STUDIES TECHNICAL SUPPORT / SPARE PARTS 36 TRAINING / INTERNATIONAL FORUM ON VACUUM DIE CASTING 37 CONTACT Company FONDAREX 3

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4 VACUUM: THE EVACUATION GENIUS 500 Our principle In pressure die casting, since filling a cavity with an alloy is extremly rapid, vacuum technology is recognized as being the most efficient solution to evacuate air and gas. With this technology, superior quality parts can be produced. Today, vacuum technology plays a key role in the production of complex and high quality parts such as structural parts. In its innovative vacuum technology, Fondarex uses two methods of guaranteeing optimum evacuation until the end of the filling phase: patented mechanical valves that close in 1 millisecond or chill-blocks with an ingenious aerodynamic profile. The Fondarex vacuum system is suitable for all production cells and molds. It is the technology peripheral device for pressure die casting (Al, Mg, Zn) providing additional injection process control. Research & Development Fondarex s research and development engineers continually strive to perfect the vacuum process in die casting and plastic injection molding. They work in close collaboration with universities, technical centers and customer partners throughout the world. Today, Fondarex counts more than 1000 customers in over 50 countries. With this perfect synergy between market and research, Fondarex continues to develop its technology to meet its customers in crea sing demands. Indeed, this is certainly one of the main reasons behind Fondarex s position as world market leader. B A ULTIMATE 4C 2000 A Standard B Optional 6 FONDAREX Technology Technology FONDAREX 7

5 MULTIFACETED PERFORMANCE VACUUM MAKES THE DIFFERENCE Our performances The specialist Your advantages 1 Consulting and expertise Integration of the vacuum system in your production cells Overall view of the casting process (mold design, injection parameters, shot sleeve / plunger system and spraying / thermo regulation system) 2 Vacuum application studies Mold adaptation and design, in particular the gating system and vacuum channels Injection parameter recommendations 3 Products, a modular vacuum system that can be tailo red to meet customers needs, compatible with all die casting machines and all molds; multilingual control panel and user manual; optional HUMIDITY SENSOR, advanced vacuum unit and EXVAC SUPERVAC vacuum valves and CHILL-BLOCK ventilation plates Products 100% made in Switzerland 4 Customization Fully customized vacuum system tailored to meet customer needs Smart options to optimize the control of the injection / vacuum process Fondarex, the leading specialist in vacuum systems can help you achieve the most difficult projects, such as auto motive structural parts, heat treated parts, thinwalled parts, surface parts and safety parts. Fondarex efficiency curves Increased density of die cast parts Improvement of surface quality (ideal for future surface treatments) Significantly less porosity Perfect filling of complex molds Allows temperature treatments (T4, T5, T6, T7) Required for welded parts More cost-effective and sustainable production thanks to reduced reject rates Fondarex vacuum systems immediately guarantee stable, efficient and cost-effective production Customer Training Regular vacuum technology training sessions at Fondarex or on-site: application studies, operation and maintenance of vacuum systems 6 Technical support Quick and efficient worldwide service Installation of vacuum systems on the production site and user training Production site troubleshooting and maintenance 7 Spare parts Spare parts are shipped within 24 hours 8 Research & Development Our team of engineers continually strives to perfect the vacuum process for pressure die casting. Close collaboration with universities, technology centers as well as customer partners throughout the world Evolution of the air pressure in the mold cavity during the injection process. mbar t Curves Standard evacuation (no vacuum) Standard vacuum Regulated vacuum example A Regulated vacuum example B 8 FONDAREX Technology Technology FONDAREX 9

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7 REINFORCEMENTS FOR PRESSURE DIE CASTING MACHINES Products FONDAREX 13

8 ECONOMY 1C Fondarex s economic vacuum system. One vacuum channel, ideal for basic applications. The essential from Fondarex, in its most modular form. Easy to use, ideal for all applications. Two independent vacuum channels for optimum flexibility. ECONOMY 1C ECONOMY 1C CENTRAL ECONOMY 1C 1000 CENTRAL FONDAREX Products Products FONDAREX 15

9 ULTIMATE 4C Fondarex perfection with a fully controlled vacuum process. Optimum for complex applications such as structural parts that require the highest performance. Two independent vacuum channels with vacuum regulation and an evacuated air volume measurement. Total process control and easy data transfer with the Ethernet pack or the USB flash drive. ULTIMATE 4C 3000 The ultimate solution from Fondarex: The most powerful and ingenious vacuum system. The best for structural parts. Four independent vacuum channels for the most extreme applications requiring a near absolute vacuum. Total process control and easy data transfer with the Ethernet pack or the USB flash drive. EXVAC CENTRAL ULTIMATE 4C CENTRAL ULTIMATE 4C 1000 ULTIMATE 4C 2000 The accessory for evacuating air from the shot sleeve. Suitable for all machines thanks to its ultra-compact design. A single vacuum channel with vacuum regulation and pollution control. 16 FONDAREX Products Products FONDAREX 17

10 THE TOTAL SOLUTION FOR STRUCTURAL PARTS We integrated our very best technologies to give you the ultimate process control. 1 Pump management system 2 Vacuum tank 3000 l 3 Vacuum pumps 3 x 160 m 3 /h 4 Control panel 5 ULTIMATE 4C 6 HUMIDITY SENSOR 7 EXVAC 8 Advanced vacuum unit 9 SUPERVAC MACRO vacuum valve 18 FONDAREX Products Products FONDAREX 19

11 HUMIDITY SENSOR The world s first look at air evacuation HUMIDITY SENSOR Patented worldwide Fondarex has developed an optical sensor capable of precisely determining the humidity content of air evacuated from the cavity. Fast, accurate and reliable, it measures and processes production data for each vacuum channel and each shot. This is the most innovative analytical equipment for vacuum die casting. Primary characteristics: Humidity measurement via a specially developed optical sensor Automatic data processing using an independent processor Limits threshold setting for process quality control Sensor self-cleaning and calibration after each shot for enhanced reliability and low maintenance Compatible exclusively with models and ULTIMATE 4C WITH HUMIDITY SENSOR (ms) Curves Humidity measurement channel A Humidity measurement channel B Tolerance threshold Selected area Out of tolerance signal 20 FONDAREX Products Products FONDAREX 21

12 Technical data: vacuum systems SWISS MADE ECONOMY 1C 250 ECONOMY 1C 1000 ECONOMY 1C CENTRAL CENTRAL 200 Die casting machine tonnage (t) < 600 approx. < 3000 approx. all < 600 approx. < 2000 approx. < 3000 approx. < 3000 approx. < 4500 approx. all < 600 approx. < 2000 approx. < 3000 approx. < 3000 approx. < 4500 approx. < 4500 approx. all < 3000 approx. < 4500 approx. < 4500 approx. all all VACUUM SYSTEM FRAME Mobile unit (on wheels) Frame and tank material Vacuum tank capacity (l) Vacuum value in the tank (mbar) External dimensions (mm) Width Depth Height Weight (kg) VACUUM SYSTEM COMPONENTS Vacuum pump BUSCH Series RA (m 3 /h) 1 x 25 1 x x 25 1 x 40 1 x 63 1 x x x 25 1 x 40 1 x 63 1 x x x x x x Automation SIEMENS HMI PLC Pneumatic system FESTO TP 700-7" S TP 700-7" S TP 700-7" S TP 700-7" S TP 700-7" S TP 700-7" S TP 700-7" S TP 700-7" S TP 700-7" S Number of vacuum channels Evacuation section of vacuum channels (mm 2 ) TP 900-9" S TP 900-9" S x x x x x x x x x x 2 x 2 x 2 x 2 x 2 x 2 x 4 x 4 x 4 x 4 x 1 x 500 Vacuum regulation system Buffer tank x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar 1 x 5 l at 6 bar Language pack (English, German, French, Italian, Spanish, Portuguese, Swedish, Turkish, Polish, Czech, Romanian, Russian, Chinese, Japanese, Korean) VACUUM SYSTEM MONITORING AND MEASUREMENTS Vacuum measurements and monitoring per vacuum channel Illustration of the vacuum curve per vacuum channel Export and storage of vacuum curves on USB (Excel) Pollution control per vacuum channel Illustration of the pollution control curve per vacuum channel Profile control per vacuum channel Illustration of the profile control curve per vacuum channel Evacuated air volume measurement per shot Leak test (mold and shot sleeve) Settings: Internal storage of settings for individual projects/molds (no. of files) / External backup/restore of settings (Excel) via MMC/USB Log data: Internal storage of production data (no. of cycles) / External backup of production data (Excel) via MMC/ USB/Ethernet Control of all types of Fondarex SUPERVAC valves and CHILL-BLOCKS Control of all valves types (other brands) Standby mode - Calibration of vacuum sensors Alarm management (process and maintenance) Error diagnostics display Recording of error log data Interface: Potential free contacts VACUUM SYSTEM OPTIONS Pump upgrade (m 3 /h) 1 x 40 2 x x 40 1 x 63 / 1 x x x x x 40 1 x 63 / 1 x x x x 160 2/3 x x x 160 2/3 x Ethernet Pack - PROFINET and/or PROFIBUS interface HUMIDITY SENSOR Advanced vacuum unit (subject to change) TP 900-9" S TP 900-9" S TP 900-9" S TP 900-9" S CENTRAL TP 900-9" S ULTIMATE 4C TP " CPU x 5 l at 6 bar 1 x 5 l System pressure ULTIMATE 4C TP " CPU x 5 l at 6 bar 1 x 5 l System pressure ULTIMATE 4C TP " CPU x 5 l at 6 bar 1 x 5 l System pressure ULTIMATE 4C CENTRAL TP " CPU x 5 l at 6 bar 1 x 5 l System pressure EXVAC TP 177-4" S FONDAREX Products Products FONDAREX 23

13 THE ORIGINAL IS BEST Products FONDAREX 25

14 VACUUM VALVES MONOVAC / SUPERVAC MONOVAC SUPERVAC MINI SUPERVAC MEDIO SUPERVAC MAXI SUPERVAC MACRO Patented worldwide MONOVAC 1 piston valve Evacuation during the first injection phase. Compression spring closure, controlled by a signal from the die casting machine. SUPERVAC Ingenuity from Fondarex: The most powerful valve in the world. Maximum evacuation until the mold is completely filled. Ultra-fast valve closure in one millisecond, using the metal s kinetic energy. Technical data: MONOVAC / SUPERVAC vacuum valves Die casting machine tonnage (t) CHARACTERISTICS Closing system MONOVAC SUPERVAC MINI SUPERVAC MEDIO SUPERVAC MAXI SUPERVAC MACRO < 400 approx Controlled closure (by compression spring) Closed by the kinetic energy of the metal Closed by the kinetic energy of the metal Closed by the kinetic energy of the metal Closed by the kinetic energy of the metal Closing time (ms) SCOPE Al / Mg Zn Shot weight Al (kg) ,3 1, Shot weight Mg (kg) ,07 1 0, Shot weight Zn (kg) - 0, TECHNICAL DATA SWISS MADE Valve Compensator Valve Compensator Valve Compensator Valve Compensator Valve Compensator Width (mm) Depth (mm) ,4 63,5 88,9 88, ,7 139,7 Height (mm) Weight (kg) 13 10,8 3 2,3 9,6 8, ,4 28,4 25,4 (subject to change) 26 FONDAREX Products Products FONDAREX 27

15 THE TALENT OF AERODYNAMICS Products FONDAREX 29

16 CHILL-BLOCKS SCCZ / SCS SCCZ 12 SCS 30 SCS 60 SCS 100 SCS 140 CHILL-BLOCKS SCS 60 / 100 / 140 Technical data: CHILL-BLOCKS SCCZ / SCS SWISS MADE Efficient evacuation until the die is completely filled. Solidification of metal in the aerodynamic profile. SCCZ (Steel Chill Compact Zinc) SCS (Steel Chill Standard) Also available with water cooling. Die casting machine tonnage (t) CHARACTERISTICS Closing system SCOPE CHILL-BLOCK SCCZ 12 CHILL-BLOCK SCS 30 CHILL-BLOCK SCS 60 CHILL-BLOCK SCS 100 CHILL-BLOCK SCS 140 < 200 approx. < 400 approx Solidification of metal in the profile Al / Mg - Solidification of metal in the profile Solidification of metal in the profile Solidification of metal in the profile Solidification of metal in the profile Zn - - Shot weight Al (kg) - 0,1 1,5 0, Shot weight Mg (kg) 0,05 0,8 0,07 1 0, Shot weight Zn (kg) 0,1 3 0, TECHNICAL DATA Fixed part Mobile part Fixed part Mobile part Fixed part Mobile part Fixed part Mobile part Fixed part Mobile part Width (mm) Depth (mm) 63,4 63, Height (mm) Weight (kg) 2,9 2,8 4,1 3,9 9,4 8,5 18,8 17,2 30,6 32,6 (subject to change) 30 FONDAREX Products Products FONDAREX 31

17 HIGH-LEVEL PRESSURE DIE CASTING Half cylinder block (Boxer 2-cylinder motorcycle) / BMW AG 2 Hydraulic control unit for gearbox / METALLWERK FRIEDRICH DEUTSCH GmbH for MERCEDES-BENZ AG 3 Cylinder block (4-cylinder motor block automobil) / BMW AG 4 Shock tower / ALBERT HANDTMANN METALLGUSSWERK GmbH & Co.KG for BMW AG 5 Door handle locking armature truck / SCHLIEPER Ges.m.b.H for VOLVO TRUCK CORPORATION 6 Car body element / DGS DRUCKGUSS SYSTEME AG for AUDI AG

18 OUR EXPERTISE Consulting and expertise With more than 60 years experience in vacuum technology, Fondarex has acquired extensive know-how that it is committed to sharing with its customers. Through specific consulting services and responsive support, the technical team provides the expertise required to ensure our customers success. Vacuum application studies Fondarex, specialist in vacuum application studies: Determines the evacuation system Sizes and adapts the gating system Sizes and adapts vacuum channels Offers advice on injection parameters A team of experts provides support to help you in the most challenging situations. 34 FONDAREX Services Services FONDAREX 35

19 AT YOUR SERVICE LESS AIR MORE KNOW-HOW Technical support Spare parts Training International Forum on Vacuum Die Casting Our team of engineers provides quick and efficient service on production sites across the world. Through its strong international presence, Fondarex maintains a close relationship with its customers. Fondarex offers a full maintenance contract that includes the regular maintenance of vacuum systems on production sites, software upgrades, ongoing training for personnel and special conditions for spare parts. The full maintenance contract ensures you achieve maximum productivity from your vacuum system: A competitive advantage. Each day, the Fondarex vacuum system delivers optimum performance. Fondarex original spare parts are made in Switzerland to guarantee the smooth operation and longevity of our products. Fondarex ships spare parts with in 24 hours. Spare parts are available locally in Switzerland, Germany, United States and China. Fondarex regularly organizes training sessions on vacuum technology, vacuum applications and how to use and maintain vacuum systems. Training sessions can be tailored to meet the interests and needs of participants, whether they are operators, service staff, engineers or managers. Training can be given on site or at our premises. Fondarex is dedicated to bringing together the main players from the pressure die casting industry: Foundrymen and metallurgists, machine and peripheral device manufacturers, die makers and scientists, as well as all other specialists involved in the field. Every three years, Fondarex organizes the International Forum on Vacuum Die Casting, in Montreux. Professionals from the industry present the latest innovations and debate on current topics and the future. 36 FONDAREX Services Services FONDAREX 37

20 Our worldwide representations: EUROPE AMERICA ASIA BULGARIA CZECH REP. ENGLAND GERMANY GREECE ITALY POLAND PORTUGAL ROMANIA SPAIN SWEDEN SWITZERLAND TURKEY ARGENTINA BRAZIL UNITED STATES CHINA INDIA JAPAN REP. OF KOREA First edition 2013 Second, expanded edition 2016 COPYRIGHT 2016 FONDAREX SA FONDAREX SA Route Industrielle St-Légier Switzerland T F FONDAREX Services

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