Westomat® VPC Dosing Furnace for Gravity Casting

The Westomat® VPC is an aluminum dosing furnace with the flexibility to fulfill even the most demanding dosing requirements with high productivity. The model displayed (Westomat® VPC 1200S) exhibits features specifically useful for aluminum dosing to sand and low pressure die casting as well as for special purpose foundry applications.

The Westomat® is equally suitable for small and large aluminum casting weights and variable pouring speeds. It has been carefully designed to dose an optimized, low turbulence metal stream into the mold – the main prerequisite for high casting quality.

Programming of the system is easily performed through a panel PC with a touch-screen. Processing data are stored in a large mold-specific database.

For the Westomat® varying casting positions poses no problems. We can fit the  dosing furnace system with a mobile platform specifically designed to meet your aluminum die casting requirements.

Westomat® dosing furnace gravity and sand casting provides maximum precision, excellent energy efficiency, high melt quality and maximum operating life. Special technical innovations also enable a significant increase in productivity during the aluminum die casting process.

VPC Dynamics Dosing Furnace Control

Designed Specifically for Gravity Castings

Based on a Siemens S7-3 control, the VPC Dynamics dosing control delivers precision over virtually every aspect of the dosing process. The modular structure ensures that the required function can be implemented quickly and simply. The VPC Dynamics is operated via a 15” touch screen control. The user interface informs the user with a single display about all conditions of the Westomat®. Thanks to the intuitively operable visualization, input times are shortened and hardly any questions arise during use. And in the exceptional case that help is needed, ‚help‘ texts and the option of an instruction manual that is fully integrated in the control unit provide further assistance.

In terms of performance, the VPC Dynamics exceeds all existing systems by far. For instance, a sand casting system has direct access to up to 10,000 die-casting programs. The VPC also detects any wear-and-tear on the heating rods and monitors the correct functioning of all power contacts.

Die Cast Mold Memory

In gravity casting, casting programs are managed by the mold memory. In a standard application 80 programmes can be stored in the memory, which an be accessed directly by the gravity casting system. The memory can optionally be expanded to up to 10,000 casting programs.

Each storage space can either store a conventional 5-stage casting program or a dynamic casting program. It is also possible to switch from a conventional to a dynamic casting program, and vice versa, without losing existing data.

Data backup function is integrated in each VPC control, which automatically saves all entered values on an additional plug-in memory card.

Teach-In Programming

If a new casting has to be set, the Westomat® is simply “taught” for optimally filling mold in gravity casting, different fill speeds. Hence, in the past, five different flow rates could already simply be entered into the VPC control with the respective flow rates assigned to each.

Now, with the benefit of the Teach-In system, the operator is able to dynamically change the dosing furnace flow rates during the dosing process by simply adjusting a hand dial. The VPC Dynamics control records this dynamic dosing process as a casting program. As the process is saved, all necessary casting parameters and adjusting factors are calculated and assigned to the current casting program.

Dosing Furnace Performance:
  • Sizes for all die-casting machines and casting capacities – 450 to 3100 kg (990 to 6,800 lbs)
  • Long refill intervals thanks to the high volume capacity
  • Easy integration in any die casting cell thanks to compact design and compatibility
  • Easy set-up of a casting program with Teach-In
  • Variable casting curve with up to five breakpoints per curve
  • High number of shape saving options
  • Easy adjustment of the casting weight by entering the data with the touch panel – no additional mechanical retooling necessary.
  • Freely programmable logic control (PLC)
  • Continuous dosing cycle even during refilling
  • High quality melt due to oxide-free metal removal below the level of the bath and constant metal temperature all the way to the metal casting chamber
  • Considerable increase in productivity of your casting cell thanks to Top-Stop-Position®
  • Energy-saving through use of high-quality insulating materials
  • Long service life of the refractory materials – many customers achieve more than 20 years.
  • Increase in the melt quality by optional use of the proven purge gas technology

Customer Application Example: Westomat® VPC

ThyssenKrupp Kloth Senking based in Hildesheim, Germany is a subsidiary of ThyssenKrupp Automotive Castings.

In 2000, after gaining the largest order ever in the Kolth Senking company history, an all-new foundry for the production of car chassis castings was erected.

For molten metal delivery, the company opted for two mobile Westomat® plants on mobile platforms servicing an automated die casting line. They ensure the precise filling of the dies in-line with Westomat® VPC’s, which met their casting process requirements.

Decisive factors for the decision in favor of further StrikoMelter® and Westomat® plants were the good experiences with respect to metal quality and reliability. With the equipment in use – StrikoMelter® and Westomat® – the desired casting quality is always reached.