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Die Casting Advance into the New Dimension for Spraying Systems with AED Automation

Editor: Nicole Kareta

Structural components are becoming increasingly important in automotive applications. In addition, there are components for electric vehicles, such as battery housings or castings for components of the 5G network. The trend towards larger components can clearly be observed. These are undisputed challenges, but also a great opportunity for die casting.

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The combination of two independent spraying systems paired with spraying tools of almost any size makes a significant contribution to cycle time savings and thus to the productivity of the line.
The combination of two independent spraying systems paired with spraying tools of almost any size makes a significant contribution to cycle time savings and thus to the productivity of the line.
(Source: AED Automation)

The production of such components requires significantly larger die casting machines. Presses in the 6000 to locking force range are already on the market, 9000 to die casting machines are being implemented. Of course, die casting machines of this size require appropriate spraying systems.

The requirements for the spraying systems can be summarized as:

  • Long ranges
  • High payloads
  • High reliability
  • Minimum (spraying) cycle times
  • Flexibility in the spraying application

In order to meet these requirements, AED Automation GmbH offers different solutions to customers. In addition to the robotic spraying systems, which cover machine sizes up to max. 6000 to, AED Automation has been offering gantry solutions for many years.

The gantry system operating two independent spraying systems (see picture) could be interesting for die casting machines beyond 5000 ton locking force in particular. One spraying system is assigned to the mobile die, the second spraying system to the fixed die. The spraying programme can thus be optimally adjusted for both dies independently of each other. Each of the two spraying systems has a payload of 270 kg. If required, even very large spraying tools can be used.

AED gantry system with two spraying systems.
AED gantry system with two spraying systems.
(Source: AED Automation)

This combination of two independent spraying systems paired with spraying tools of almost any size makes a significant contribution to cycle time savings and thus to the productivity of the line.

In order to optimally adapt the spray program to the requirements of the die, the spray gantry has 16 independently programmable spray circuits. The spraying gantry also offers the option of working with conventional water-based release agents as well as the option of minimum quantity spraying.

The strokes of the gantry are designed for 8000 to die casting machines and easily cover the necessary travel distances. Optionally, the vertical axis can be supplied in a telescopic version in case of restrictions in the available height under the crane way.

Further customer benefits result from the small space requirement of the system. Due to the additional horizontal axis, the spraying system can be moved out of the area between the platens to the side. This makes maintenance work and changing of the spraying tool easier for the user.

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