LH- Customized Double Cycle Mold Temperature Controller For Die Casting Machine Mold

• Customized double-cycle mold temperature controller, specialized for die-casting machine molds: aluminum alloy auto parts (engine brackets), cookware (30cm pots), and industrial components (pump housings)—enables separate temperature control for mold cavity and core.

• Features water/oil dual-medium compatibility: water medium (50-120℃) for low-temperature die-casting, oil medium (120-300℃) for high-temperature alloys (e.g., A380), adapting to diverse B2B production needs.

• Achieves ±0.1℃ temperature control precision via dual PID system—eliminates die-casting part defects (warpage, porosity) caused by temperature fluctuations.

• Integrates double independent cycles: 2 sets of heating/cooling systems for simultaneous cavity (e.g., 180℃) and core (e.g., 160℃) temperature control—improves part dimensional consistency by 40%.

• Supports 5-50L/min adjustable flow rate and 50+ custom temperature curves (for complex mold heating processes), compatible with 50-5000T die-casting machines.

• Complies with global standards (ISO 9001, CE, UL) and supports MES integration, suitable for B2B export to die-casting factories, auto parts suppliers, and cookware manufacturers.

Visually, the controller has a compact, stainless steel cabinet—sleek (1200×800×1500mm) to fit die-casting workshop layouts without blocking mold access. When you touch the 7-inch touchscreen, it feels smooth and responsive (anti-scratch glass) with clear, die-casting-specific icons (e.g., “Cavity Temp,” “Oil Flow”)—no confusing menus. The water/oil inlet valves have color-coded handles (blue = water, red = oil) that are easy to grip and turn (no slippery plastic). During operation, the internal pump emits a soft hum (55 decibels)—quieter than a desktop printer—while the LED temperature display glows steadily (green = stable, red = adjusting). You’ll notice the cavity and core temperatures stay within ±0.1℃ of set values (e.g., 180℃ and 160℃) — no fluctuations that cause warpage. After 8 hours of use, the leak-proof valves show no seepage (tested with soapy water), and the energy monitor displays 8kW/hour (33% less than their old controller). Every detail—from the mold size compatibility label to the emergency stop button— is designed to make die-casting mold temperature control safe, efficient, and profitable for B2B users.

• Double Independent Cycles Cut Part Rejection by 40%: The controller’s 2 separate heating/cooling systems enable cavity/core temperature difference control (0-50℃ adjustable)—critical for complex parts like auto brackets. A Chinese factory reduced warpage-related rejects from 18% to 10.8%, saving 360kg of aluminum monthly (worth $1,440). Each cycle has independent PID tuning: e.g., set cavity to 180℃ (for part surface finish) and core to 160℃ (for internal structure)—no more one-size-fits-all heating. For multi-cavity molds, this ensures uniform temperature across all cavities (variation <1℃), cutting reject rates by an extra 15%.

• ±0.1℃ Precision Ensures Dimensional Consistency: The dual PID control system uses platinum resistance sensors (accuracy ±0.05℃) to maintain temperature stability— a U.S. cookware factory producing 30cm pots reduced thickness variation from ±0.1mm to ±0.05mm (meeting EN 12983 standards). The controller’s auto-tuning function (10-minute calibration per mold) eliminates manual guesswork— a Mexican die-casting factory cut mold change time from 2 hours to 30 minutes, adding 120 extra parts/day. For high-precision parts (e.g., 0.8mm-thin sensor brackets), the precision prevents porosity (leak test pass rate rose from 90% to 99.5%).

• Water/Oil Dual-Medium Adaptability Saves Equipment Costs: The controller works with both water (50-120℃, low-cost for cookware) and oil (120-300℃, high-temperature for A380 auto parts)—no need to buy 2 separate controllers. A Thai factory saved $15,000 by replacing 2 single-medium controllers with 1 double-cycle unit. The medium switch takes 5 minutes (no pipe disassembly) — ideal for factories with mixed die-casting needs (e.g., aluminum cookware + auto parts). The oil medium uses food-grade thermal oil (meets FDA standards) for cookware molds—no contamination risk.

• Energy Efficiency Cuts Electricity Bills by 33%: The variable-frequency pump adjusts flow rate (5-50L/min) based on mold size—uses 8kW/hour for 200kg molds vs. 12kW/hour for fixed-speed pumps. A Chinese factory reduced monthly electricity costs from \(9,000 to \)6,030, saving $35,640 annually. The controller’s heat recovery system captures waste heat from cooling (reuses 20% for heating)— a European factory cut energy use by an extra 10%, meeting EU energy efficiency standards (ERP Directive). For 2-shift operations, this translates to a 14-month ROI on the controller’s premium cost.

• **Leak-Proof Design Protects Molds (Saves \(25,000/Year)**: The water/oil circuits use double-seal valves (PTFE + nitrile rubber) and pressure sensors (0.1MPa accuracy)—detect leaks within 10 seconds and shut off the medium. A Chinese factory avoided \)25,000 in mold damage after a valve leak was stopped automatically. The circuits are also pressure-tested to 1.0MPa before delivery—no initial leaks. The oil medium uses anti-oxidation additives (extends oil lifespan by 50%)— a Brazilian factory reduced oil replacement from 3x/year to 2x/year, saving $3,000/year.

• Auto Aluminum Brackets (A380, 8kg/Part): Ideal for complex brackets requiring cavity/core temperature difference (180℃/160℃). A Chinese auto supplier reduced warpage rejects from 18% to 10.8%, saving $17,280/year and passing Ford’s OEM audit. The 36kW high power heats large molds (1500×1000mm) in 20 minutes—30% faster than single-cycle controllers.

• Aluminum Cookware (ADC12, 3kg/Pot): Water medium (90℃) ensures uniform pot wall thickness (±0.05mm), reducing hot spots. A European cookware brand cut spray painting rework by 40% (no uneven surfaces) and saved $35,640/year in energy costs, meeting IKEA’s supplier standards.

• Industrial Pump Housings (A356, 12kg/Part): Oil medium (220℃) enhances housing strength (tensile strength 260MPa, ISO 6892-1). A U.S. pump manufacturer reduced warranty claims by 60% (no porosity leaks) and protected molds from oil damage, saving $25,000/year.

• High-Precision Sensor Brackets (ADC12, 0.5kg/Part): ±0.1℃ precision prevents porosity (leak test pass rate 99.5%), meeting automotive sensor standards (ISO 16232). A German electronics factory increased daily output by 120 parts (faster mold heating), meeting a $800,000 order.

• System Structure & Advantages:

• 2 Independent Circuits: Cavity circuit (Heating Unit 1 + Pump 1) and core circuit (Heating Unit 2 + Pump 2)—no cross-contamination between mediums.

• Dual PID Tuning: Each circuit has separate proportional-integral-derivative parameters—e.g., cavity uses faster response (for surface finish) and core uses slower response (for internal structure).

• Medium Switch Valves: 3-way valves (stainless steel) enable quick water/oil switch—no pipe disassembly, saving 1 hour per medium change.

• B2B Benefits for Die-Casting:

• Reduces Rejects: Independent temperature control cuts warpage/porosity by 40%—saves 360kg aluminum/month for a 200kg/day factory ($1,440/month).

• Saves Time: Auto-tuning and separate circuits cut mold change time by 75% (2 hours to 30 minutes)—adds 120 parts/day.

• Cuts Costs: Eliminates need for 2 single-cycle controllers—saves $15,000 in equipment investment.

• Medium Selection Guide:

• Water Medium: Best for ≤120℃ (cookware, low-temperature alloys) — low cost, easy maintenance, no oil contamination.

• Oil Medium: Best for >120℃ (auto parts, A380) — high thermal stability, uniform heating for thick parts.

• Component & Performance Checks:

• Valves/pumps sourced from Bosch Rexroth (leak-proof test: 1.0MPa for 24 hours) — reject rate <0.5%.

• Temperature sensors (PT100) calibrated via NIST-traceable equipment—accuracy ±0.05℃ guaranteed.

• 100-hour continuous operation test: Maintain ±0.1℃ precision, no leaks, energy consumption ≤15kW/hour.

• Global Compliance:

• Meets ISO 9001 (quality), CE (EN 60204 for electrical safety), UL (for U.S. markets), and GB/T 19830 (Chinese standards).

• For food-grade cookware: Uses FDA-approved thermal oil and water circuits (no heavy metal leaching).

• Documentation & Validation:

• Provide calibration certificates, leak-test reports, and energy efficiency certificates for B2B audits.

• On-site validation: Test with your mold (e.g., 30cm pot mold) for 3 days—ensure temperature precision and compatibility before handover.

• Pre-Operation Checks (5 Minutes/Day):

1. Medium Level Inspection: Check water tank (≥50% capacity) and oil tank (≥40% capacity)—add distilled water/thermal oil if low (avoid tap water with impurities).

1. Temperature Calibration: Verify sensor accuracy with a portable calibrator (deviation ≤0.1℃ allowed)—recalibrate via touchscreen if needed.

1. Leak Test: Apply soapy water to valves/pipes—no bubbles allowed (shut down and replace valve if leak detected).

1. Circuit Check: Ensure cavity/core circuits are set to correct medium (water/oil) — avoid medium mismatch (damages heating unit).

• Weekly Maintenance (1 Hour):

1. Clean Filters: Remove water/oil filters (located at inlets) and rinse with compressed air—clogged filters reduce flow rate by 30%.

1. Inspect Valves: Check valve handles for smooth operation—apply silicone lubricant if stiff (avoids leaks).

1. Update Curves: Backup custom temperature curves to USB—prevents data loss from power failure.

• Monthly Maintenance (2 Hours):

1. Oil Change (for Oil Medium): Replace thermal oil every 6 months (or 500 hours)—use only recommended oil (we provide a list) to avoid pump damage.

1. Sensor Recalibration: Recheck PT100 accuracy—replace sensor if deviation >0.1℃ (critical for precision parts).

1. Energy Audit: Review energy consumption data (via touchscreen) — adjust flow rate/power if usage exceeds 15kW/hour.

• Power & Flow Customization: Increase power to 45kW (for large molds >2000mm) or reduce to 6kW (for small sensor molds). A U.S. aerospace factory ordered 45kW models—heats 2500×1800mm molds in 15 minutes, meeting a $2M order.

• Medium Upgrade: Add a water-oil heat exchanger (reuses oil waste heat for water heating)—cuts energy by 25%. A European factory used this to meet EU ERP standards, saving $8,500/year.

• Automation Integration: Add MES/ERP connectivity (OPC UA protocol) for real-time temperature monitoring and remote control. A Chinese auto supplier tracks 10 controllers via SAP—reduces on-site monitoring labor by 50%.

• Mold Compatibility: Customize pipe sizes (1/2”-2”) and connector types (threaded/quick-connect) for non-standard molds. A Brazilian factory ordered quick-connect pipes—cuts mold change time by an extra 10 minutes.

• Warranty Coverage: 2-year warranty for the controller body; 1-year warranty for valves/pump. For high-volume factories, extend valve warranty to 1.5 years (50% extra cost)— a Chinese client saved $4,500/year in replacements.

• 24/7 Technical Support: 4 temperature control engineers (10+ years in die-casting) offer round-the-clock help via phone/WhatsApp/video. For urgent leaks (e.g., during auto part order rush), respond within 15 minutes—85% resolved remotely in 1 hour.

• Spare Parts Supply: Stock valves, pumps, and sensors in 3 warehouses (China, Germany, U.S.). 24-hour delivery— a Mexican factory received a replacement valve in 16 hours, minimizing downtime to 1 shift.

• On-Site Training: Free 2-day training for your team—covers double-cycle operation, auto-tuning, and leak troubleshooting. A Thai factory’s team reduced controller-related defects by 12% after training, mastering “medium switch for mixed production.”

• Specialization in Die-Casting Temperature Control: We don’t make generic controllers—we focus on double-cycle systems for die-casting molds, understanding their unique needs (cavity/core control, medium adaptability). Our R&D team tests every unit with real die-casting molds (ADC12/A380) to solve B2B pain points.

• Proven B2B Track Record: Over 200 die-casting factories in 38 countries use our controllers, including suppliers to Ford, IKEA, and Bosch. A Chinese auto supplier increased annual revenue by $1.2M after using our controllers to meet OEM standards.

• Transparent ROI for B2B Operations: We provide a customized ROI calculator (based on energy costs, rejects, and labor). Most clients recoup investment in 14-18 months—for a 200kg/day factory, this means $180,000 in 5-year savings (energy + rejects + mold protection).

• Die-Casting Expertise: We offer free mold temperature consultations (e.g., “best medium for A380 brackets”) and custom curve design. A U.S. cookware brand used our advice to reduce heating time by 30%, winning a $800,000 IKEA order.

• Flexible Lead Times: Standard models (9-36kW) are in stock (delivery 7-10 days). Customized models take 15-20 days—40% faster than competitors. A European factory received a 45kW custom controller in 18 days, meeting a $1M holiday rush order.

• Q1: Is this controller compatible with our existing 500T die-casting machine and 1500×1000mm auto bracket mold?

• Q2: How difficult is it to train our operators (no double-cycle experience) to switch between water and oil mediums?

• Q3: Can the controller handle our 250℃ high-temperature requirement for A380 auto parts (our old controller maxes out at 220℃)?

• Q4: What is the controller’s water/oil consumption, and can it operate in our 380V 3-phase workshop with voltage fluctuations?