Finding where a die-casting cell loses time

A digital twin of a high-pressure die-casting cell: a cycle tracker that splits every shot into its phases and holds them against plan, die temperatures and cooling-water flows, and an advisor that says where the loss is and what to do about it. The data is simulated; orbit the cell, switch on the thermal view and follow the cycle step by step.

What's on the screen

The 3D cell. The holding furnace, the ladler, an 840-tonne cold-chamber die-casting machine, the extraction robot, the quench tank and the trim press all move on the same cycle. The thermal view maps the die surface temperature onto the model; the inside view shows the metal filling the die during the shot.
The cycle. Every shot is split into seven phases: die spray, closing, ladling, shot, solidification, opening and extraction. Each phase's actual time sits next to its plan, so the gap shows up in the phase it belongs to.
Die and shot data. Die temperatures from four thermocouples, the water flow in each cooling circuit, and the last shot's curve: plunger velocity and pressure along the stroke.
The advisor. It matches the gap in the cycle with the data that changed in the same period. Here, solidification runs 3.9 seconds over plan; the T3 area of the die runs about 20 °C hotter than the others, and the flow in circuit 3, which cools that area, is below nominal. It names what to check and what the loss costs per shift at this rate.

How to try it

Use the camera buttons to move between areas of the cell, or drag to orbit.
Click a phase in the list on the left and the cycle jumps to it. Change the speed in the bar below, or scrub the cycle back and forth along it.
"Show on the die" on the advisor card switches on the thermal view and marks the hot area.
"Watch the film" plays the same scene full screen as a 26-second walkthrough.

In a real installation

Everything on this page is simulated: the cell, the machine, the part and the data are representative. In a real cell, the cycle phases and the shot data come from the die-casting machine's control system, die temperatures from thermocouples and water flows from flow meters on the cooling circuits. The advisor's rules are set up for that cell's plan, die and product.

We run the same analysis on your machines, with your data. If you are thinking about it for your own line, write to us with your machine list and the data sources you have.