“When General Motors Corp. selected L.K., as their supplier for new 3000 ton Machines, they did so as a partner to L.K. offering their considerable experience and highly developed specifications, while L.K. offered the latest in die casting machine capability and technology together with considerable economies of scale from a producer of 1,800 die casting machines per year. L.K.’s global technical team worked continuously with the Bedford team to produce a die casting machine that meets the needs and specifications of General Motors. Surprisingly, it wasn't the big items that got the most attention, as L.K.’s closing and shot ends are designed for performance, but it was the small items that got the most attention, from electrical and hydraulic components, to fittings and connectors. In the end, all areas of the machine design were closely
examined, resulting in a machine design that exceeds the most comprehensive machine specifications available anywhere.

The first machine, and the ones to follow feature L.K.’s latest real time shot system technology with the capability to produce transmission cases and engine blocks. Each machine is equipped with L.K.’s new shot control and monitoring system, CAST Advantage™, with options for both open and closed loop control. The CAST Advantage system also provides advanced shot system diagnostic capabilities as well as our NEW “Dynamic Force™” profile feature to capture shot force applied to the metal at the end of shot. Together with our ultra-fast end-of-shot deceleration, users can monitor the combined static and dynamic components of the end-of-shot force and react to changes in the process that produce undesirable flash.

These machines also feature quick die change capabilities such as quick die clamps to secure the dies to the platens, cylinders to assist in cover die removal, precision die carriers to simplify die changes,and mobile carriers to manage die hoses and cables. To complete the die casting cell, a modular post processing cell was designed to minimize labor by automating inspection, overflow and runner removal, part marking, inspection, and rack loading.

The entire system is controlled by an Allen-Bradley Guard Logix controller, equipped with two Panel View touch screen HMI’s. From the HMI’s, the operator can view the status of all equipment in the system, including the extract and spray robots, as well as the operational settings and status of the die casting machine, While this is a large, comprehensive die casting machine control system, considerable effort was made to ensure that start-up and recovery from stoppages was simplified so that operators could initiate a new cycle with minimal effort from the main HMI.

To complete the delivery, L.K. has deployed a site Program Manager, and Lead Project Engineer both residing in Bedford, IN. This team, along with other L.K. global team members., will provide onsite support during the machines installation and commissioning.