Total Thermal Vision (TTV) System

The Total Thermal Vision (TTV) system uses infrared technology to monitor the surface temperatures of the die during the die casting process of light alloys. A completely new architecture provides a more compact system featuring an integrated, optimized cooling system, smaller, electric shutters and compact connectors, as well as a smarter IR camera. Additionally, the use of a PLC is no longer required, providing more flexibility for customer configuration.

The thermal imaging camera includes a high-performance infra-red camera housed in a protective casing and thermally isolated from the surrounding environment, guaranteeing a perfect image of the die each time regardless of the installation distance. The TTV control unit comes equipped with a 21.5-in. touchscreen with a graphic interface and Marposs’ E9066T Flat Panel industrial computer for data collection, measurement, and control. It has up to 4 IR camera connections, and both the camera and controller units are specifically designed to operate in aggressive foundry environments. 

Correct temperature distribution on the die surface is crucial in guaranteeing the efficiency and quality of the die casting process. Shrinking, porosity, cracking, blistering and a host of other defects may arise from an incorrect optimization of the thermal distribution on the die. The TTV system can be used in high and low-pressure die casting as well as gravity die casting, helping users analyze, understand and improve their processes.

Thermal imaging cameras are easy to install inside the casting cells and are positioned to frame the die between the moment the newly produced die cast is removed and the preparation for the next cast. Cameras are equipped with acceleration, humidity, temperature, and pressure sensors, which continuously monitor the operating state of the camera, guaranteeing precise, correct thermographic images regardless of the operating conditions. TTV’s overall benefits include:

• Reduced process costs
• Increased die lifespan
• Optimized cycle times
• Increased system efficiency (OEE)
• Analysis of the process variables and errors
• Reduced unscheduled process stops