GENERGY MANUFACTURING

INNOVATION IN THE VERTICAL DIE CASTING MACHINES

We currently have Gencast-100, 100 Ton Vertical Diecast Machines In Stock ready to ship!

Gencast series presses

The Gencast Series is the result of input from customers, maintenance personnel, and years of experience. The Gencast has been designed to simplify operation and maintenance of the machine by taking advantage of ethernet communication, using advanced system monitoring, and streamlining hydraulics.

ReLIABILITY

SIMPLICITY

PRODUCTIVITY

Ethernet

Ethernet device communication on the machine provides real time data on machine cycle, cooling circuits and faults to the operator. The ethernet device level ring provides redundant communication in the machine or automated cell, allowing the system to operate if a cable is damaged. The Genergy team can also troubleshoot the system remotely, tweak programming, and monitor system performance. Ethernet communication significantly reduces the amount of wiring which eliminates over head wire ways, and makes installation exceptionally fast.

Ethernet on-machine I/O reduces wiring while providing real time status of sensors and switches to the operator on the HMI

On-machine I/O and pneumatic units eliminate wiring to pneumatic valves and simplify wiring to limit switches associated with the pneumatic systems.

Distributed I/O over ethernet reduces wiring from the main panel to ethernet and power. The use of Safety I/O eliminates banks of safety relays in the main panel

System Monitoring

Aside from ethernet communication, the Gencast has advanced monitoring systems in the cooling circuit, molten aluminum level and front guard that protect the operator, personnel and machine.

Cooling system

The cooling system incorporates sensors that monitor temperature and flow through the main circuits of the machine. Temperature and flow data is displayed on the HMI and sensor in addition to the machines PLC. This provides positive confirmation that essential systems operate in appropriate ranges, which prevents damage to the machine by giving early indications of inadequate cooling.

Individual sensors monitoring water circuits

Aluminum and Ladle

The Genergy team employs a system using a precisely calibrated over head sensor and servos driving the ladle to smoothly transfer repeatable amounts of aluminum from the furnace into the shot well without sloshing. Gone are the days of cleaning the probes that detect aluminum level and hopefully if not always prevent the ladle from over shooting into the furnace.

Front Guard

The front guard of a die cast machine is the last line of defense for the operator and other personnel in case of blowout. As such the guard system is essential for safe operation. The traditional front guard is a dance between the pneumatic cylinders driving the door and hydraulic cylinders driving the shuttle. The only sure way to not crash the shuttle into the door is to only allow shuttle movement when the door is fully open. This extends cycle time in the critical pour to shot window. To reduce cycle time the door can be timed to close as the shuttle enters the machine. With the shuttle not tied to a known position of the door the shuttle and door could crash, resulting in damage to the machine and downtime.

The Gencast addresses the traditional front guard tension between known position and speed by driving the front door with a servo driven electric cylinder. This allows precise positioning of the guard door: the door only needs to go high enough to clear rotors and tooling. Cycle time from pour to shot is reduced while eliminating the possibility of crashing the shuttle into the door.

Streamlined Hydraulics

There are no welded lines on the Gencast. Manifold orientation eliminates most of the shot extend and retract lines and reduces the distance that hydraulic fluid travels to get to the cylinder. The result is lower fluid shock, in the system, fewer potential leak points, and no cracked welds. The remaining lines are formed tubes that can be ordered and replaced without any welding or additional modification.

Valve stacks for peripheral systems are located on the hydraulic power unit providing easy access to maintenance personnel.

The hydraulic layout also accelerates installation time.

No welded lines to or from the shot cylinder.

Preformed bent tubes are easily replaced. No welding required.

Peripheral valves mounted on power unit for easy access and servicing.

Gencast Machine Sizes

The Gencast Series comes in a range of sizes to accommodate any sized rotor production.

Gencast 100

100 Ton Clamp Force
11" Shot Well
38lbs Aluminum Capacity

Gencast 200*

200 Ton Clamp Force
13" Shot Well
83lbs Aluminum Capacity

Gencast 300*

300 Ton Clamp Force
16" Shot Well
109lbs Aluminum Capacity

*Available in Stretched Frame configuration for a larger daylight opening.

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