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Based on the mold parameters and process requirements provided by the user (the upper and lower molds and the center mold must be heated to 170°C simultaneously), and in combination with the key points for mold temperature controller selection found in the search results, the following are recommended power and oil pump selection for two mold temperature controllers:
I. Mold Temperature Controller Power Selection
1. Heating Power Calculation
Heating power must be calculated based on mold weight, temperature differential, specific heat capacity, and heating time. The formula is:
KW = W × Δt × C / (860 × T)
W: Mold weight (kg) (1.5t each for the upper and lower molds = 1500kg, 3t for the center mold = 3000kg)
Δt: Temperature differential (170°C - 20°C ambient temperature = 150°C)
C: Specific heat capacity (0.11 for steel molds)
T: Heating time (assuming 1 hour)
Calculation Example:
Power of a single mold temperature controller for the upper and lower molds:
KW = (1500 × 2) × 150 × 0.11 / (860 × 1) ≈ 57.6 kW (considering heat loss, a 20% redundancy is recommended, so 70 kW is selected).
Middle die temperature controller power:
kW = 3000 × 150 × 0.11 / (860 × 1) ≈ 57.6 kW (same as 70 kW).
Manufacturer Recommendation:
Large-tonnage molds (e.g., 3-ton middle molds) require higher power to ensure preheating time. Refer to the configuration of molds in die-casting machines over 800 tons (24 kW/mold). However, the user requires overall heating, so a comprehensive calculation is required.
2. Temperature Control Accuracy and Stability
The die-casting process requires temperature control accuracy within ±1°C. A PID or PLC control system equipped with a high-precision temperature sensor is required.
Dual-circuit or multi-circuit designs are more suitable for molds with multiple oil channels to ensure temperature uniformity.
II. Oil Pump Selection
1. Flow and Pressure Requirements
Flow calculation: The total oil channel volume and circulation speed must be met. Volume of a single oil channel (diameter 19mm = 1.9cm, length 11m = 1100cm):
V = πr² × L = 3.14 × (0.95)² × 1100 ≈ 3125cm³ = 3.125L/channel.
Total flow rate for the upper/lower molds: 8 oil channels, 4 inlet and 4 outlet, total volume 25L. A recommended circulation flow rate ≥ 100L/min is recommended (to ensure rapid heat exchange).
Flow rate for the middle mold: Similar calculations are required, requiring ≥ 80L/min.
Pressure requirements:
Long and multi-branched oil channels require a high-pressure pump (≥ 4bar) to overcome resistance. A magnetic drive pump (high-temperature resistant and with backflow support) is recommended.
2. Oil Pump Type and Characteristics
Fixed-flow pumps: Simple structure, suitable for stable flow requirements; variable-flow pumps: Energy-saving but costly, suitable for fluctuating flow scenarios.
Material: High-temperature thermal oil (up to 350°C) requires a stainless steel pump body and high-temperature resistant seals (such as fluororubber).
III. Comprehensive Selection Recommendations
Mold Temperature Controller Configuration:
Upper/Lower Mold Temperature Controller: 70kW heating power, 100L/min flow rate, 4 bar pressure, dual-circuit design.
Middle Mold Temperature Controller: 70kW heating power, 80L/min flow rate, 4 bar pressure, single-circuit design (multiple circuits are required for temperature zoning).
Additional Features:
Air-blowing and oil-return function (recovers thermal oil during mold changes).
PLC control, supports temperature curve programming and fault logging.
Safety and Energy Efficiency:
Overtemperature protection, low-liquidity alarm, and other safety features.
Energy-saving variable frequency pump design reduces long-term energy consumption.
IV. Precautions
Heat transfer fluid: High-temperature synthetic oil (such as a biphenyl-diphenyl ether mixture). Change regularly (annually recommended).
Pipe Connections: Use 19mm diameter metal spiral tubing to minimize heat loss.
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Post time: Aug-11-2025
