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In response to the production requirements of a certain new energy motor housing casting on the 3500T die-casting island, AODE provided an integrated solution of "high-precision mold temperature control + intelligent point cooling" - equipped with 4 double-loop mold temperature controllers and a 120-channel point cooling system. This successfully addressed common defects such as mold sticking, cold segregation, shrinkage porosity, deformation and gas pores in the industry, helping the customer achieve high yield and stable mass production.
The structure of the new energy motor housing is complex, with significant variations in wall thickness, and extremely high requirements for the uniformity and dynamic stability of the mold temperature field. This product is made by aluminum die casting, and the core process window is extremely narrow:
• Mold temperature: 190–230℃ (optimal 200 ± 5℃)
• Aluminum liquid temperature: 650–680℃ (adjusted according to mold temperature)
01 Four double-loop mold temperature controllers, enabling independent temperature control for the moving and fixed molds in separate zones
Each molding temperature machine supports dual independent outputs, and four machines work together to cover multiple critical heat areas of the mold. Through differentiated configuration of oil temperature (150–220℃) and water temperature (80–120℃), different positions are maintained within the preset optimal mold temperature range, significantly reducing the temperature difference between the moving and fixed molds as well as in different areas, and effectively preventing warpage deformation risks from the very beginning.
02 A set of 120-channel point cooling machines, for eliminating thermal hotspots at specific points
Apply cold air cooling for 2-5 seconds at high intensity to achieve localized cooling. Then switch to circulating water for 8-15 seconds to maintain balanced heat dissipation. Finally, use air blowing for 1-2 seconds to dry the water channels, preventing water accumulation from interfering with the next cycle. This timing control can precisely match the die-casting cycle, ensuring that the solidification speed of the heat-affected area is synchronized with the surrounding structure, and significantly improving the internal density.
Analysis of Defect Types and Causes: AODE Solution - High Temperature of Mold Molding Port/Chamfer / Mold Temperature Too High - Lower Mold Temperature + Strengthening Points Cold + Optimize Iron Content (0.7–1.0%) Cold Gap / Insufficient Filling Mold Temperature Too Low - Increase Mold Temperature + Reduce Cooling Intensity Shrinkage / Shrinkage Cavities Heat Joint Cooling Slow Points Cold + Thicken Cooling + Overflow Warping / Deformation Large Temperature Difference Zone Temperature Control + Dynamic and Static Mold Balance Air Porosity / Leakage Mold Temperature Fluctuation Large Stable Temperature + Vacuum + Exhaust
