Case Sharing | Is the Thermal Runaway Rate in Die Production Reduced to 0%? This Company Did It!

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Every remarkable industrial product we admire owes its existence to the precision craftsmanship of die makers.

All of this relies heavily on the robust support of the mould industry.

Dies are the "Mother of Industries" and the cornerstone of manufacturing, playing a very vital role. During the production process of dies, even slight temperature changes can have a significant impact on product quality. Infrared thermal imaging cameras can effectively prevent product defects such as cracks, bubbles, and sand holes caused by uncontrolled die temperature.

Two real cases are shared here to present die-casting related companies and see how thermal imaging cameras can show their prowess in die production.

Case 1: Temperature Detection of Auto Part Dies

① About the User

It is a precision die-casting company in Suzhou. This foreign-funded enterprise produces auto parts and has strong precision die manufacturing capabilities.

② User's Pain Points

During the operation of the ejector die (movable die) and cavity die (fixed die) in high-pressure die casting, common die defects including shrinkage porosity, gas entrapment, hot tearing, and die-casting porosity frequently manifest.

③ Solution

This user uses the PL Series intelligent infrared thermal imaging camera to accurately measure the temperature change of the die during the die-casting process and generate visualized thermal images, effectively avoiding the adverse effects of excessively high or low die temperatures on the quality, service life, production cycle, and so on of parts.

④ User's Evaluation

This user recognizes the temperature detection effect of PL. It can not only see the temperature data of various parts of the die, but also assist in data analysis and process optimization. Moreover, the equipment operation is very simple and stable.

Case 2: Temperature Detection of Wind Turbine Blade Dies

① About the User

It is an energy company in Henan and a professional manufacturer of generators, wind turbines, and blowers.

② User's Pain Points

Wind turbine blades are made of double-sided die-casting after die glue filling, heating, and shaping. They are large in size, making it difficult for technicians to pay real-time and comprehensive attention to the die-casting process and seek an efficient and comprehensive temperature detection solution.

③ Solution

In the die production workshop, PL Series intelligent infrared thermal imaging cameras are used to detect the blade surface temperature in real time during die-casting. They can timely find out uneven heating and abnormal temperature during glue filling and heating, so as to efficiently locate the root cause of die pressing problems.

④ User's Evaluation

The user said that in the thermal images of the PL Series, the high and low temperature areas are very obvious, and abnormal temperatures can be located at a glance, which effectively helps them ensure product delivery quality, while effectively reducing defective rates and saving production costs.

Application Advantages

➤  Non-contact temperature measurement without interrupting the production process

Non-contact measurement of die surface temperature distribution, no need to interrupt the production process, avoiding interference and ensuring the safety of inspectors

➤ Real-time detection with intuitive presentation of heating or cooling process

Real-time tracking of the entire die-casting process, intuitive presentation of die temperature changes during heating or cooling processes, and accurate control of the process

➤ Ensuring product quality with efficiency increased

Accurate presentation of uneven thermal distribution and potential thermal hazard areas, prevention and prompt detection of problems, reducing both scrap rate and production costs, and bringing significant economic benefits to enterprises

➤  Optimizing die design and manufacturing

The temperature distribution heat map can provide an important reference for die design and manufacturing. Engineers can optimize the structure and material selection of dies, improve the performance and life of dies, and further improve product quality

Introduction to Products in Application

The PL Series intelligent infrared thermal imaging camera used in the above two cases won Red Dot Design Award in 2023, the "Oscar" of the world design field. Moreover, it has a powerful "core" and a built-in high-sensitivity infrared detector developed by Guide. Five resolutions and multiple lenses can be freely selected to match the needs of various detection scenarios in the die industry.