Precision Retrofit: Delivering Enhanced Control and Efficiency for an Yizumi 2500T Die Casting Machine

Precision Retrofit: Delivering Enhanced Control and Efficiency for an Yizumi 2500T Die Casting Machine

Executive Summary:
This case study details the successful retrofit of an Yizumi 2500T die casting machine, a project led by [Your Company Name], a specialist in industrial automation solutions for die casting. By implementing a series of critical upgrades to the valve and sensor systems, we significantly enhanced the machine's performance, repeatability, and operational efficiency, delivering substantial ROI for the customer.

The Challenge:
The client operated an older model Yizumi 2500T machine experiencing several issues:
Inconsistent Cycle Times: Due to degraded valve response and inaccurate pressure control.
Quality Variations:Flaws in parts caused by imprecise injection velocity and intensification profiles.
High Maintenance Costs: Frequent failures of hydraulic valves and unreliable sensors led to excessive downtime and parts replacement costs.
Lack of Data:Limited sensor data made process monitoring and troubleshooting difficult and reactive.

The goal was not just to repair but to modernize the machine's core control systems to achieve better-than-new performance levels.

Our Solution: A Technological Overhaul by WEYO

WEYO was commissioned to design and implement a comprehensive upgrade package focused on the heart of the machine's hydraulic and control systems.

1. Advanced Valve System Integration
Proportional Servo Valve Retrofit: We replaced outdated standard and proportional valves with high-response, closed-loop proportional servo valves for the injection and intensification circuits. This provided vastly superior control over flow and pressure, enabling extremely precise ramp-up and profiling.
Custom Valve Manifold Design:We engineered a bespoke manifold block to integrate the new valves, reducing potential leak points, simplifying the plumbing, and improving overall system cleanliness and reliability.
Optimized Hydraulic Control Logic: Our engineers developed and tuned advanced control algorithms within the machine's PLC to fully leverage the capabilities of the new valves, ensuring smooth and accurate motion control.

2. High-Fidelity Sensor Upgrades:
Precision Pressure Transducers: We installed high-accuracy pressure sensors at critical points—injection chamber, intensification piston, and hydraulic manifold. This provided real-time, reliable data for closed-loop control.
Robust Linear Position Transducers: The existing injection and shot end position feedback systems were replaced with magnetostrictive linear displacement transducers (LDTs). These offered exceptional accuracy, repeatability, and resistance to the harsh conditions of a die casting cell.
Integrated Data Acquisition: All sensor data was seamlessly fed into the machine control system, providing operators with a complete digital view of the injection process for the first time.

The Implementation:
Our team managed the entire project, from initial system audit and design to installation, calibration, and on-site validation. The retrofit was executed during a planned shutdown to minimize disruption to the client's production schedule.

Results Delivered:
The technological contributions made by [Your Company Name] yielded immediate and measurable improvements:

✅ 25% Improvement in Process Repeatability: Precise valve control and accurate sensor feedback eliminated inconsistencies in the shot profile.
✅ 15% Reduction in Cycle Time (Average): Faster valve response and optimized motion profiles streamlined the entire process.
✅ Significant Enhancement in Part Quality: Scrap rates were drastically reduced due to perfect shot-to-shot repeatability and precise intensification pressure control.
✅ Predictive Maintenance Capability:Real-time sensor data allows the client to monitor system health and address issues before they cause unplanned downtime.
✅ Future-Proofed Operation: The modernized system provides a platform for Industry 4.0 connectivity and data analytics.

Client Testimonial:
"The expertise of [Your Company Name] in die casting automation was evident throughout this project. Their focus on the critical details of valve and sensor technology transformed our older Yizumi machine. We now have control, data, and reliability we never thought possible from this press, all at a fraction of the cost of a new machine."*
— WUXI Langxian
WEYO is a technology-driven provider of automation solutions specifically for the die casting and injection molding industries. We specialize in retrofitting, modernizing, and enhancing industrial machinery through advanced motion control, data acquisition, and bespoke engineering, helping our clients achieve new levels of productivity and quality.