Uneven distribution of mold temperature can lead to many defects in the die-casting process, such as peeling, porosity, shrinkage, and depositionTTV monitors temperature maps before and after the lubrication phase to detect any changes and prevent malfunctions from occurring. This can reduce the number of rejected parts related to various stages of the process, such as warm-up, die setting, and part production.

TTV enables the determination of what is called R O. The key points for monitoring castings in the controlled area of I (related zone) and the related temperature range.

The core of the TTV system consists of a controller and a thermal imaging camera device, designed specifically for operation in extremely harsh casting environments.

Both thermal imaging camera devices are equipped with high-performance infrared sensors and image processing electronic components, which are placed in sturdy stainless steel housings for protection. Pneumatic louvers are used to protect the outer shell equipped with germanium glass (infrared penetrable), and air is sprayed to clean the windows during the die-casting process.

There are two different types of thermal imaging camera devices, and their differences are reflected in the size of the housing and the quality of the infrared sensor:

• TC120： Thermal imaging camera device with an outer diameter of 120 mm and a fixed optical sensor
• TC168： Thermal imaging camera device with an outer diameter of 168 mm and an autofocus optical sensor

The fixed focus thermal imaging camera is mainly used to monitor the production of parts that are similar to each other, with no significant changes in the die structure. However, for flexible production, a high-performance camera is required due to the large variation in the distance between the die structure and the thermal imaging camera and the control target. The camera is equipped with an autofocus device, which is automatically managed by the TTV system control electronics.

Install the device in the machine tool so that the moving and fixed parts of the die can be manufactured when the device is fully opened.

The installation distance depends on the area of the die being monitored. The optical components of the camera determine the physical size of the constructed image (25 ° or 45 °). The relationship between the distance between the camera and the target, the optical components used, and the subsequent pixel size (in millimeters) is shown in the following table.

Imaging&Optical Data

Distance distance

Image size Image size

Resolution Resolution

The temperature map of the die surface can be automatically saved before and after the lubrication stage without increasing the cycle time. The temperature distribution chart provides the thermal equilibrium conditions of the die and the data required to improve the cycle and optimize the production process.

The TTV operator interface includes a touch screen that presents a real-time temperature map of the die, and if the measured temperature value is higher or lower than one or more ROI limits, an alarm will be issued in a timely manner. The interface will also present the temperature of the die in the form of images.

Store all collected data locally or store all collected data on a network server. Then, these data are used for post-processing analysis, which is a fundamental prerequisite for modern digital die-casting production (Casting 4.0).

For more information, please clickTTV - Total Thermal Vision.

• Reduce process costs
• Extend the service life of stamping dies
• Optimize cycle time
• Improve System Efficiency (OEE)
• Analyzing process variables and errors
• Reduce unplanned process shutdowns
• Identify parts

For all technical features, please refer to the table in the download section.