WO2025238403A1

WO2025238403A1 - Hydraulic self-adjusting die carrier

Info

Publication number: WO2025238403A1
Application number: PCT/IB2024/054777
Authority: WO
Inventors: Jonathan Patrick WEILER; Mehdi FARROKHNEJAD; Gordon ALBLAS
Original assignee: Magnesium Products of America Inc
Current assignee: Magnesium Products of America Inc
Priority date: 2024-05-16
Filing date: 2024-05-16
Publication date: 2025-11-20
Anticipated expiration: 2026-11-16

Abstract

A die carrier includes a first end and a second end opposite the first end, the first end being connected to the second end via a frame. The die carrier also includes at least one hydraulic assembly disposed within the frame, the at least one hydraulic assembly including a hydraulic jack. The hydraulic jack is structured to extend away from the frame responsive to a load applied to the die carrier.

Description

HYDRAULIC SELF-ADJUSTING DIE CARRIER

TECHNICAL FIELD

[0001 ] The present disclosure relates to die casting and, more specifically, die carriers within a die casting clamp mechanism.

BACKGROUND

[0002] Die casting mechanisms or assemblies can be used to form molded products by applying high pressures at high speeds to various, typically molten, casting material. Die casting assemblies can include a die disposed between platens, where molten casting material is then formed within the die. Die casting assemblies can be adapted for use across a variety of materials having different mechanical properties. However, various casting materials can, based on their mechanical properties, require more or less pressure and speed as well as elevated temperatures to form the molded product, which can overtime cause degradation and/or damage to components within the die casting assembly.

[0003] It would be advantageous to provide a method and system for preventing/delaying degradation or damage within a die casting assembly.

SUMMARY

[0004] One aspect of the present disclosure relates to a die carrier. The die carrier includes a first end and a second end opposite the first end, the first end being connected to the second end via a frame. The die carrier also includes at least one hydraulic assembly disposed within the frame, the at least one hydraulic assembly having a hydraulic jack. The hydraulic jack is structured to extend away from the frame responsive to a load applied to the die carrier.

[0005] In various embodiments, the at least one hydraulic assembly includes a first hydraulic assembly and a second hydraulic assembly. In some embodiments, the first hydraulic assembly is disposed at the first end and the second hydraulic assembly is disposed at the second end. In other embodiments, the die carrier further includes at least one sensor disposed on the frame and operably coupled to the at least one hydraulic assembly, where the at least one sensor is configured to sense the load applied to the carrier. In yet other embodiments, the die carrier includes at least one controller in communication with each of the at least one sensor and the at least one hydraulic assembly, where the hydraulic jack is structured to extend responsive to a determination by the at least one controller that the load satisfies a threshold. In various embodiments, the frame includes a middle region disposed between the first end and the second end, where the middle region is axially offset from each of the first end and the second end. In some embodiments, the die carrier includes a shoe portion disposed on a bottom surface of each of the first end and the second end. In other embodiments, the die carrier includes a locator plate disposed on a top surface of each of the first end and the second end.

[0006] Another aspect of the present disclosure relates to a die cast assembly. The die cast assembly includes a die structured to form a molded part from a casting material, and a die carrier structured to support the die. The die carrier includes a first end and a second end opposite the first end, the first end being connected to the second end via a frame. The die carrier further includes at least one hydraulic assembly disposed within the frame, where the hydraulic jack is structured to apply a first responsive load to the die to prevent sagging of the die within the die cast assembly.

100071 In various embodiments, the hydraulic jack is structured to apply the first load responsive to a second load applied to the die carrier. In some embodiments, the die cast assembly includes a first platen and a second platen, wherein the die is disposed between the first platen and the second platen. In other embodiments, the first platen is a moving platen and the second platen is a stationary platen. In yet other embodiments, the die cast assembly also includes at least one sensor disposed on at least one of the first platen or the second platen, the at least one sensor configured to sense a third load applied to at least one of the first platen or the second platen. In various embodiments, the frame includes a middle region disposed between the first end and the second end, the middle region being axially offset from each of the first end and the second end. In some embodiments, the casting material comprises magnesium.

[0008] This summary is illustrative only and should not be regarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

(0009] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

[001 1 FIG. l is a side view of a die cast assembly, according to an embodiment.

[0011] FIG. 2 is a schematic representation of a side view of the die cast assembly of FIG. 1, according to an embodiment.

[0012] FIG. 3 is a perspective view of the die cast assembly of FIG.1, according to an embodiment.

[0013] FIG. 4 is a perspective view of a die within the die cast assembly of FIG. 1, according to an embodiment.

[0014] FIG. 5 is another perspective view of the die of FIG. 4, according to an embodiment.

[0015] FIG. 6 is a perspective view of the die cast assembly of FIG. 1 near an interface between the die and a die carrier, according to an embodiment.

[0016] FIG. 7 is a side view of the die cast assembly of FIG. 1, near the interface between the die and the die carrier, according to an embodiment.

[0017] FIG. 8 is a schematic representation of a sectional view of the die cast assembly of FIG. 1 taken along line 8-8 of FIG. 1, according to an embodiment.

[0018] FIG. 9 is a sectional view of the die cast assembly of FIG. 1, taken along line 8-8 of FIG. 1, according to an embodiment. [0019] FIG. 10 is a side view of a locator pin of the die within the die cast assembly of FIG.

9, according to an embodiment.

[0020] FIG. 11 is a perspective view of the die carrier and the die within the die cast assembly of FIG. 1, according to an embodiment.

[0021] FIG. 12 is a perspective view of a base rail within the die cast assembly of FIG. 1, according to an embodiment.

[0022] FIG. 13 is a bottom perspective view of the die within the die cast assembly of FIG. 1, according to an embodiment.

[0023] FIG. 14 is a schematic representation of an end view of a die carrier within the die cast assembly of FIG. 1, according to an embodiment.

[0024] FIG. 15 is a schematic representation of a side view of the die carrier of FIG. 14, according to an embodiment.

[0025] FIG. 16 is schematic representation of a top view of the die carrier of FIG. 14, according to an embodiment.

[0026] FIG. 17 is a perspective view of the die carrier of FIG. 14, according to an embodiment.

[0027] FIG. 18 is a perspective view of a bracket within the die carrier of FIG. 17, according to an embodiment.

[0028] FIG. 19 is a top perspective view of the base rail and a die carrier within the die cast assembly of FIG. 1, according to an embodiment.

[0029] FIG. 20 is a side perspective view of the base rail and a die carrier within the die cast assembly of FIG. 1, according to an embodiment.

[0030] . DETAILED DESCRIPTION

[00311 Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0032] The present disclosure relates to pressure die casting. Generally, die casting can be used in high volume applications to form molded products. During the casting process, pressure and/or heat is used to force (or pour) molten casting material into molds or dies to create the molded product. The casting material can be or include various nonferrous metallic materials (e.g., nonferrous metallic alloys such as magnesium-based alloys). Typically, die casting can be carried out using die cast assemblies, which include two platens — a stationary platen and a moving platen, between which a die is positioned. Force applied to the exterior of the two platens forces the moving platen toward the stationary platen, clamping the die therebetween.

[00331 Generally, die cast assembly can be used for a variety of different casting materials. Depending on the specific type and mechanical properties of the casting material, more or less pressure, Speed and/or heat may be applied to form the molded product. Components of the die cast assembly, such as the die and platens, are sized to accommodate the particular casting material based on a needed pressure amount and/or a size of the die (and size of the desired molded product). During operation of the die cast assembly, sagging of the die can occur due to the weight of the die, the size of the die, and/or temperature variations. During use, the die cast assembly is subject to significant changes in temperature and, accordingly, corresponding thermal expansion on large tooling within the die cast assembly can interfere with operation of the die carrier within the assembly and the shot sleeve. Furthermore, expansion of the die halves can cause misalignment therebetween. For example, depending on the application, a first half of the die (e.g., cover) can run hotter than a second half of the die (e.g., ejector). This misalignment can cause sagging and a parting line shift of the ejector half of the die when then die is open, which can then lead to breaking of the die core, drag on die cast assembly components, and/or damage to the die core, among other issues. Sagging can lead to excessive wear and degradation of die cast assembly components and reduce the life of the die cast assembly in production. The present disclosure relates to a die cast assembly that includes an adjustment mechanism to self-adjust or self-correct a positioning of a die within the die cast assembly to reduce impact of sagging and resulting wear on surrounding die cast assembly components.

[0034] Referring now to FIGS. 1 and 2, alternate side views of a die cast assembly 10 are shown, according to various embodiments. In various embodiments, the die cast assembly 10 is a hydraulic self-adjusting die carrier assembly (HSAD). The die cast assembly 10 is structured to include an adjustment mechanism to facilitate self-adjustment to correct die positioning during operation to mitigate the effects of sagging and wear on components within the die cast assembly 10.

[0035] As shown in FIGS. 1-3, the die cast assembly 10 includes a first platen 15, a second platen 20, and a die 30 disposed between the first and second platens 15, 20. In various embodiments, the first platen 15 is a moving platen (e.g., ejector platen), structured to move relative to the second platen 20. During operation of the die cast assembly 10, the first platen 15 may be forced toward the second platen 20 to sandwich the die 30 therebetween. In some embodiments, the first platen 15 is forced toward the second platen 20 via one or more clamping cylinders, rods, or other actuators known in the art. In various embodiments, the second platen 20 is a stationary platen, structured to remain in place throughout die casting processes. In various embodiments, the first platen 15 and/or second platen 20 may include or consist of a hardened steel alloy. In some embodiments, the first platen 15 and/or second platen 20 may include or consist of one or materials determined by a manufacturer. In some embodiments, each of the first platen 15 and the second platen 20 may include a stainless steel face. In some embodiments, the first platen 15 may include a cast steel with internal cores to facilitate fusion within the die 30. In other embodiments, the second platen may include a normalized forged steel (e.g., AISI 1020, UNI C30, etc.). [0036] As shown, the first and second platens 15 and 20 may include at least one guide pin 25 (or tie rod), which extends through each platen. In various embodiments, the at least one guide pin 25 (“tie bar”) is structured to provide lateral stability, which, in addition to other benefits, facilitates protection to piping, wiring, and other susceptible components within the die cast assembly 10. That is, the at least one guide pin 25 can be structured to guide travel of the first and second platens 15 and 20, and/or to facilitate locking the die cast assembly 10 within a die cast machine. As shown in FIGS. 4-6, each of the pins 25 may extend through respective openings 27, which may be formed by the notches 33 (or recesses) disposed within the die 30, and apertures through the first platen 15 and second platen 20. Each of the pins 25 is coupled to the second platen 20 via one or more fasteners (e.g., tie bar screws). As shown, at least one of the first platen 15 or the second platen 20 may include at least one bushing 35, through which the at least one pin 25 may extend. Accordingly, during operation of the die cast assembly 10, the first platen 15 may slide relative to the second platen 20 as the at least one bushing 35 slides relative to the at least one guide pin 25. In various embodiments, the die cast assembly 10 is structured such that each of the first platen 15, the second platen 20, and the die 30 are substantially rectangular in shape. In some embodiments, the die cast assembly 10 may include four pins 25, each pin 25 being disposed within a corner of each of the first platen, 15 and second platen 20. In such embodiments, the first platen 15 may include four bushings 35 such that each pin 25 extends through and articulates with a corresponding bushing 35.

[0037] As shown in FIGS. 4-8, the die 30 is disposed between the first platen 15 and the second platen 20. In various embodiments, the die 30 is supported by at least one die carrier 100, which is positioned below a bottom surface of the die 30. As appreciated from FIG. 4-6, the die 30 is structured to engage with an upper surface of the at least one die carrier 100 such that the die carrier 100 axially supports the die 30. In various embodiments, the die 30 includes at least one tie bar carrier block (or “stand off’) 37, which may be disposed on a bottom surface of the die 30. The at least one stand off 37 is structured to engage with an upper surface of the at least one die carrier 100 to create clearance between the die 30 and the at least one die carrier 100, which facilitates protection of piping, wiring, and other components within the die cast assembly 10. In some embodiments, the at least one stand off 37 is disposed to contact a hydraulic jack within the at least one die carrier 100. In some embodiments, the at least one stand off 37 is not structured to support the weight of the die 30. Although FIG. 4-6 show the die 30 including two stand offs 37, in various embodiments, the die 30 can include any number (e.g., 1, 2, 3, 4, 5, 12) of stand offs 37.

[0038] As shown in FIG. 7, the second platen 20 extends in a substantially vertical direction such that it is parallel to the first platen 15. The second platen 20 may be joined to a base rail 42, which extends in a substantially horizontal direction from the second platen 20. The base rail 42 may be structured as a support, upon which the first platen 15 and the die carrier 100 may rest. As shown in FIGS. 6-7, the die carrier 100 can be anchored to or rest upon a surface of the base rail 42 such that the die 30 is ultimately supported by the base rail 42. In other embodiments, the second platen 20 is structured to couple to the base rail 42. In such embodiments, the base rail 42 may form part of a base frame within the die cast assembly 10.

[0039] In various embodiments, the die cast assembly 10 includes two die carriers. For example, as shown in FIG. 7, the die cast assembly 10 may include a first die carrier 100 and a second die carrier 200. In some embodiments, the first die carrier 100 is a cover die carrier, which may be configured to support a cover portion of the die 30. In other embodiments, the second die carrier 200 may be an ejector die carrier, which may be structured to support an ejector portion of the die 30. In various embodiments, the first die carrier 100 and the second die carrier 200 can be structured to include the same or similar components.

[0040] FIG. 8 shows a sectional view of the die cast assembly 10 taken along line 8-8 of FIG. 1. As shown, the die carrier 100 is arranged beneath the die 30 such that each of the stand offs 37, which are disposed on a bottom surface of the die 30, rests on or otherwise engages with a top portion (e.g., an upper surface of) 105 of the die carrier 100. The die carrier 100 may include a first end 110 and a second end 112, where each of the first end 110 and the second end 112 are connected by a frame 118. As shown in FIGS. 8-9, a top portion of each of the first and second ends 110, 112 are structured to engage with or support the die 30 and a bottom portion 120 of the frame 118 is structured to engage with or be supported by the base rail 42 of the second platen 20. Each of the first end 110 and the second end 112 also engage with or are supported by first and second rails 116 and 117, respectively, which are disposed within the base rail 42. Accordingly, as shown in FIGS. 8-11, the first and second ends 110, 112 of the die carrier 100 are disposed a distance above the frame 118, which rests within a region of the base rail 42 disposed between the rails 116 and 117. Accordingly, during operation of the die cast assembly 10, the die carrier 100 may bear weight resulting from not only the die 30 itself, but from any expansion resulting from forming the molded part from the casting material.

[0041 | In various embodiments, the die 30 may include one or more locator pins 44, which extend away from the die 30 toward the die carrier 100. In some embodiments, the one or more locator pins 44 are structured to be received within one or more apertures, recesses, grooves, or other features of the die carrier 100 to facilitate placement of the die 30 upon the carrier 100. In various embodiments, the die 30 may include a locator pin 44 disposed on opposite sides of the die such that the die includes a first locator pin 44 disposed on a side of the die 30 structured to be supported by the first end 110 of the carrier and a second locator pin 44 disposed on a side of the die 30 structured to be supported by the second end 112. As described previously, in some embodiments, the die cast assembly 10 may include a first die carrier 100 and a second die carrier 200, such as shown in FIG. 11. Accordingly, in some embodiments, the die 30 can include multiple pairs of locator pins 44 to facilitate alignment with both the first die carrier 100 and the second die carrier 200.

[00421 As shown in FIG. 12, when the die carrier 100 is positioned on the base rail 42, the first end 110 is supported by the first rail 116 and the second end 112 is supported by the second rail 117. Accordingly, the frame 118 of the die carrier 100 is positioned within a valley created between the first rail 116 and the second rail 117. In various embodiments, the frame 118 may be disposed below a top surface of each of the first and second rails 116, 117. In other embodiments, the frame 118 may be disposed at a same or similar height as a top surface of the first and second rails 116, 117. As shown in FIG. 12, the second carrier 200 may be structured to engage with the base rail 42 in the same or similar manner as the carrier 100. The die 30, which is shown in FIG. 13, may be structured such that the stand offs 37 extend across both the first carrier 100 and the second carrier 200. In some embodiments, a first standoff 37 or a first set of stand offs 37 may engage with the first carrier 100 and a second standoff 37 or a second set of stand offs 37 may engage with the second carrier 200. For example, the die 30 can include a cover portion 48 and an ejector portion 46, where each of the cover portion 48 and the ejector portion 46 include a pair of stand offs 37. In various embodiments, the cover portion 48 includes a pair of stand offs 37 that engage with the die carrier 100 and the ejector portion 46 includes a pair of stand offs 37 that engage with the die carrier 200.

[0043] FIGS. 14-16 show alternate schematic representations of the die carrier 100, according to various exemplary embodiments. As illustrated, the die carrier 100 is structured such that the first end 110 and the second end 112 are axially offset from a middle region 125 of the frame 118. With such an arrangement, the first end 110 may engage with the first rail 116 and the second end 112 may engage with the second rail 117. Accordingly, the middle region 125 of the frame 118 may then rest between the first and second rails 116, 117 to be supported by an upper surface of the base rail 42. Although FIG. 14 shows the first and second ends 110, 112 formed within the frame 118 such that the frame 118 slopes downward from the ends 110, 112 toward the middle region 125, in other embodiments, the frame 118 may instead have a U-shape such that the ends 110, 112 extend upward from the middle section 125. In various embodiments, the slope of the frame 118 provides clearance to enable access to the bottom of the die 30 and other components within the die cast assembly 110.

[0044] As shown in FIGS. 14-16, each of the first end 110 and the second end 112 include a first locator bracket (“outside locator bracket”) 148 coupled thereto. Each of the first end 110 and the second end 112 further include a second locator bracket (“inside locator bracket”) 147, which is disposed inward (i.e., toward a central axis of the frame 118) of the first locator bracket 148. Each of the first locator bracket 148 and the second locator bracket 147 is structured to couple to a pin 25, which extends through a channel 130 formed between the first and second locator brackets 148, 147. In some embodiments, the first locator bracket 148 is structured to couple to the base rail 42 via a cylinder anchorage 152, such as shown in FIG. 17.. In various embodiments, the first locator bracket 148 and/or the second locator bracket 147 may be integrally formed with the frame 118. In other embodiments, the first locator bracket 148 and/or the second locator bracket 147 may be separately coupled thereto..

[0045] As shown in FIGS. 14-17, the die carrier 100 may also include a die support plate 135, which is structured to engage with and support a portion of the bottom surface of the die 30. The die carrier 100 may also include at least one locator plate 137 (“outside locator plate”), which is disposed outward from the support plate 135 (i.e., further from a central axis of the frame 118). As shown, the locator plate 137 may be structured to couple to the first locator bracket 148 and the support plate 135 may be structured to couple to the second locator bracket 147. During operation, the locator plate 137 and/or the support plate 135 may be coupled to the pin 25 to provide axial and lateral stability within the die cast assembly 100. In various embodiments, the locator plate 137 may be coupled to the pin 25 via one or more fasteners 139. In some embodiments, the one or more fasteners 139 may include one or more screws (e.g., tie bar locking screws).

[0046] As shown in the figures, the die carrier 100 may also include one or more locator pins 136 at each of the first end 110 and the second end 112. For example, in various embodiments, the one or more locator pins 136 may be disposed on an upper surface of the support plate 135. In various embodiments, each of the one or more locator pins 136 is structured to couple to or engage with a locating feature (e.g., aperture, recess, groove, etc.) disposed within the die 30. In various embodiments, each of the ends 110, 112 may include four locator pins 136, such as shown in FIG. 16. For example, in some embodiments, each of the ends 110, 112 may include four locator pins 136 arranged about the edges of the support plate 135. In such embodiments, two locator pins 136 may be disposed toward a first edge of the support plate 135 disposed nearest the middle region 125 and another two locator pins 136 may be disposed toward an edge of the support plate 135 opposite the second edge and further from the middle region 125. In various embodiments, the locator pins 136 may also be evenly distributed between opposing sides of the die carrier 100, as shown in FIGS. 15-16. [0047] As shown in FIGS. 14-17, each of the first end 110 and the second end 112 include a shoe portion 140 disposed on a bottom surface of the frame 118. The shoe portion 140 may be structured to engage with or be coupled to an upper portion of each of the first rail 116 and the second rail 117. In various embodiments, the shoe portion 140 may include one or more features to facilitate ease of positioning of the die carrier 100 onto the base rail 42. For example, in some embodiments, each shoe portion 140 may include one or more protruding portions structured to engage with a corresponding recess, groove, or other complementary feature disposed on the first rail 116 and/or the second rail 117. In other embodiments, the shoe portion may include a plate, which is structured to distribute load to each of the rails 116, 117.

[0048] During operation of the die cast assembly 10, the die carrier 100 may be subject to load patterns beyond a weight of the die 30 due to the nature of the casting process. For example, the die carrier 100 may be subject to additional load resulting from expansion of casting material within the die 30, and/or from expansion of the die 30 itself due. Excess load on the die carrier 100 may cause sagging or other misalignment between the die 30 (which is supported by the die carrier 100) the first and second platens 15, 20. To overcome the misalignment, the die carrier 100 may include one or more hydraulic assemblies 145 disposed within the frame 118. As shown in FIGS. 14 and 17, the die carrier 100 may include two hydraulic assemblies 145. In some embodiments, a first of the two hydraulic assemblies 145 may be disposed near the first end 110 and a second of the two hydraulic assemblies 145 may be disposed near the second end 112. As illustrated, each hydraulic assembly 145 may be disposed within or adjacent an inclined section of the frame 118 that connects between each of the first and second ends 110, 112 and the middle region 125.

[0049] Each of the hydraulic assemblies 145 is structured to engage with the frame 118 and a bottom portion of the die 30 such that the hydraulic assemblies 145 may exert a force onto the die 30 if necessary to correct a misalignment (i.e., due to displacement). For example, in some embodiments, the hydraulic assemblies 145 may be structured lift the die 30 to correct a misalignment (i.e., due to displacement). As shown, each of the hydraulic assemblies 145 includes a hydraulic jack 155, which is coupled to a mount 150, where the mount 150 is correspondingly coupled to the frame 118. In various embodiments, each mount 150 may include a ring or base. Each of the hydraulic jacks 155 may also include an upper region that is structured to engage with a bottom portion of the die 30 such that expansion of the hydraulic jacks 155 exerts a force on the bottom portion of the die 30 (e.g., on a bottom portion of the cover portion 48 or the ejector portion 46). Accordingly, during use of the die cast assembly 10, when casting material is provided to the die 30 (e.g., via pouring, forcing, injecting, etc.), the die carrier 100 may exert a force on the die 30 to counteract sagging (or other displacement or misalignments) resulting form expansion of the casting material within the die 30. In some embodiments, the second locator bracket 147 may include one or more protruding features 153 disposed on an outer side of the bracket 147 (i.e., outside the channel 130) such that the one or more protruding features 153 are disposed near or adjacent a hydraulic assembly 145, as shown in FIG. 18. For example, in some embodiments, the one or more protruding features 153 may be a bracket key. Accordingly, during operation, the protruding features 153 may facilitate placement and alignment of the one or more hydraulic assemblies 145 relative to the die 30.

[0050] As shown in FIGS. 14 and 16, the die carrier 100 may include one or more rail supports 160 disposed on the bottom portion 120 of the frame 118. In various embodiments, the die 30 (and the die carrier 100) may be structured to move (e.g., slide) within the die cast assembly 10 relative to the second platen 20. In such embodiments, the rail supports 160 may be structured to facilitate unidirectional sliding of the die carrier 100 parallel to a longitudinal axis of the die cast assembly 100. In various embodiments, each of the rail supports 160 may be structured to receive or engage with one or more corresponding features of the base rail 42 to facilitate smooth, unidirectional movement therebetween.

[00511 In yet other embodiments, the die carrier 100 may include one or more sensors disposed on or within the frame 118. In such embodiments, the one or more sensors may be configured to receive a load signal (e.g., axial force, pressure, expansion, displacement, etc.) corresponding to a load applied to the die carrier. In some embodiments, the one or more sensors may be operatively coupled to the at least one hydraulic assembly 145. Accordingly, in various embodiments, the at least one hydraulic assembly 145 may be configured to expand (i.e., extend the hydraulic jack 155) to engage with the die 30 to apply a load thereto. In some embodiments, each of the hydraulic assemblies 145 and the one or more sensors are operably coupled to a controller, where the controller is configured to receive one or more signals from the one or more sensors and control the hydraulic assemblies 145 in response.

[0052] In various embodiments, the at least one hydraulic assembly 145 is structured to apply a load to the die 30 responsive to the one or more sensors determining the die has displaced a threshold distance from a predetermined setpoint. In various embodiments, the amount of applied load and corresponding required hydraulic pressure within the at least one hydraulic assembly 145 is calculated by the controller based on a weight of the die 30 and a size of the at least hydraulic assembly 145. For example, in some embodiments, the controller may calculate a target hydraulic pressure required to lift the die by determining a ratio of an air pressure to a pump pressure. Accordingly, the controller can then activate the at least one hydraulic assembly 145 (e.g., via one or more servo valves) to achieve a target hydraulic pressure. In some embodiments, if the controller determines that the target hydraulic pressure is insufficient for displacing the die 30 within a time interval (i.e., based on feedback signals from the one or more sensors), the controller can activate the at least one hydraulic assembly 145 to increase the hydraulic pressure therein by a nominal amount (e.g., 1 psi) until sufficient pressure has been generated to cause displacement of the die 30. In some embodiments, the target hydraulic pressure can be determined or set, at least in part, based on a set time interval. In other embodiments, if the controller determines the target hydraulic pressure is too great, such as by determining a displacement of the die is greater than a target amount (i.e., via feedback signals from the one or more sensors), the controller can activate one or more bleed valves within the at least one hydraulic assembly 145 to reduce the hydraulic pressure.

[0053] In various embodiments, the at least one controller may be a non-transitory computer readable medium or processor, having computer-readable instructions stored thereon that when executed cause the controller to carry out operations called for by the instructions. In various embodiments, the controller may be a computing device. In yet other embodiments, the controller may be configured as part of a data cloud configured to receive commands from a user control device and/or a remote computing device. The controller may include a power source, a memory, a communications interface, and a processor. In other embodiments, the controller may include additional, fewer, and/or different components.

[0054] In some embodiments, the at least one controller may be configured to operate the hydraulic assemblies 145 responsive to a load sensed by the one or more sensors. In other embodiments, the at least one controller may operate the hydraulic assemblies 145 responsive to a sensed load (by the one or more sensors) satisfying a threshold amount. In other embodiments, the at least one controller may be configured to operate the hydraulic assemblies 145 based on at least one control signal received from a secondary controller or coupled user device. For example, in some embodiments, the at least one controller may be configured to cause the hydraulic assemblies 145 to apply a load to the die 30 (to cause displacement thereof) in response to the one or more sensors sensing a load that satisfies or exceeds a threshold amount. Additionally or alternatively, the at least one controller may be configured to cause the hydraulic assemblies 145 to apply a load to the die 30 (to cause displacement thereof) in response to a signal received from a user device — such as to adjust an alignment of the die cast assembly 10 prior to forming a molded part.

[0055] In various embodiments, the one or more sensors may be disposed along a surface of the frame 118. In other embodiments, the one or more sensors may be disposed at one or both of the first end or the second end 112. In yet other embodiments, the one or more sensors may be disposed on a portion of at least one of the first platen 15 or the second platen 20. In such embodiments, placement of the one or more sensors on at least one of the first platen or second platen may enable detection of loads that may not only cause sagging and misalignment, but also induce excess strain on the guide pins 25 (i.e., tie rods).

[0056] As described above, the die cast assembly 10 may include more than one die carrier.

In various embodiments, the die cast assembly 10 includes the first die carrier 100 and the second die carrier 200, as shown in FIGS. 19-20. In various embodiments, elements 105-160 of the first die carrier 100 are respectively equivalent to the elements 205-260 of the second die carrier 200. Accordingly, as shown in FIGS. 19-20, each of the first die carrier 100 and the second die carrier 200 may include at least one hydraulic assembly 145 or 245, respectively. During operation, the first die carrier 100 may be disposed below the cover portion 48 of the die 30 and the second die carrier 200 may be disposed below the ejector portion 46 of the die 30. Thus, during operation of the die cast assembly 10, the controller may be configured to activate the at least one hydraulic assembly 145 within the first die carrier 100 responsive to at least one signal from the at least one sensor that a displacement of the cover portion 48 exceeds a predetermined setpoint. Similarly, the controller may be configured to activate the at least one hydraulic assembly 245 within the second die carrier 100 responsive to at least one signal from at least one sensor that a displacement of the ejector portion 46 exceeds a predetermined setpoint. In various embodiments, the predetermined displacement setpoint of the cover portion 48 is the same as the predetermined displacement setpoint of the ejector portion 46. In other embodiments, the predetermined displacement setpoint of the cover portion 48 is greater than the predetermined displacement setpoint of the ejector portion 46. In yet other embodiments, the predetermined displacement setpoint of the cover portion 48 is less than the predetermined displacement setpoint of the ejector portion 46.

[0057] As indicated above, the die cast assembly 10 may be used to form molded products from a variety of different cast materials. In various embodiments, the die cast material may include an aluminum portion. The aluminum portion may include at least one of a 1000 series, 2000 series, 3000 series, 4000 series, 5000 series, 6000 series, 7000 series, or 800 series aluminum alloy. In such embodiments, the 1000 series aluminum alloy (i.e., 1050, 1060, 1070, 1100, 1145, 1199, 1350, etc.) is substantially pure aluminum with a minimum 99 wt% aluminum content and may be work hardened. The 2000 series aluminum alloy (i.e., 2011, 2014, 2024, 2036, 2048, 2090, 2091, 2099, 2124, 2195, 2218, 2219, 2319, 2618, etc.) is alloyed with copper and may be precipitation hardened to strengths comparable to steel. The 3000 series aluminum alloy (i.e., 3003, 3004, 3005, 3102, 3103, 3105, 3303, etc.) is alloyed with manganese and may be work hardened. The 4000 series aluminum alloy (i.e., 4006, 4007, 4015, 4032, 4043, etc.) is alloyed with silicon. The 5000 series aluminum alloy (i.e., 5005, 5010, 5019, 5026, 5050, 5052, 5056, 5059, 5083, 5086, 5154, 5182, 5252, 5254, 5356, 5454, 5456, 5457, 5652, 5657, 5754, A13Mg, etc.) is alloyed with magnesium and offer enhanced corrosion resistance. The 6000 series aluminum alloy (i.e., 6005, 6009, 6010, 6060, 6061, 6063, 6063A, 6065, 6066, 6070, 6081, 6082, 6101, 6105, 6151, 6162, 6201, 6205, 6262, 6351, 6463, etc.) is alloyed with magnesium and silicon and is machinable, weldable, and may be precipitation hardened. The 7000 series aluminum alloy (i.e., 7005, 7039, 7049, 7050, 7068, 7072, 7075, 7079, 7116, 7129, 7175, 7178, 7475, etc.) is alloyed with zinc and may be precipitation hardened to the highest strengths of any aluminum alloy, with a tensile strength up to 700 MPa. The 8000 series aluminum alloy (i.e., 8011, 8090, etc.) is alloyed with elements which are not covered by 1000-7000 series aluminum alloys.

[0058] In at least one embodiment, the die cast material may include a magnesium portion. In some embodiments, the magnesium portion may include at least one magnesium alloy. The magnesium alloy may include, but is not limited to AE42, AE44, AM20, AM40, AM50, AM60, AM60B, AS21, AS41, AZ31, AZ61, AZ63, AZ80, AZ81, AZ91, Elektron 21, Elektron 675, EZ33, HK31, HM21, HZ32, KIA, LA141, LA103, LAZ43, Ml, MIA, QE22, QH21, WE43, WE54, ZC63, ZC71, ZE41, ZK10, ZK20, ZK30, ZK40, ZK51, ZK60, ZK61, ZM21, ZMC711, any alloys with magnesium contents of 80% of higher, or a combination thereof. In various embodiments, the magnesium layer may include AM60B magnesium alloy, which includes about 5.5-6.5% aluminum (Al), about 0.24-0.6% manganese (Mn), at most about 0.22% zinc (Zn), at most about 0.1% silicon (Si), at most about 0.01% copper (Cu), at most about 0.005% iron (Fe), at most about 0.002% nickel (Ni), balance magnesium (Mg), and trace impurities.

[0059| In yet other embodiments, the die cast material may include one or more zinc portions, such as a zinc alloy. In various embodiments, [0060] Notwithstanding the embodiments described above in FIGS. 1 - 20, various modifications and inclusions to those embodiments are contemplated and considered within the scope of the present disclosure.

[0061] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0062] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

(0063] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. [0064] The construction and arrangement of the elements of the SPR joint as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied.

[0065] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above.

10066] Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. For example, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Also, for example, the order or sequence of any process or method steps may be varied or resequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A die carrier comprising: a first end and a second end opposite the first end, the first end being connected to the second end via a frame; and at least one hydraulic assembly disposed within the frame, the at least one hydraulic assembly comprising a hydraulic jack; wherein the hydraulic jack is structured to extend away from the frame responsive to a load applied to the die carrier.

2. The die carrier of claim 1, wherein the at least one hydraulic assembly comprises a first hydraulic assembly and a second hydraulic assembly.

3. The die carrier of claim 2, wherein the first hydraulic assembly is disposed at the first end and the second hydraulic assembly is disposed at the second end.

4. The die carrier of claim 1, further comprising at least one sensor disposed on the frame and operably coupled to the at least one hydraulic assembly, the at least one sensor configured to sense the load applied to the carrier.

5. The die carrier of claim 4, further comprising at least one controller in communication with each of the at least one sensor and the at least one hydraulic assembly, the hydraulic jack is structured to extend responsive to a determination by the at least one controller that the load satisfies a threshold.

6. The die carrier of claim 1, wherein the frame comprises a middle region disposed between the first end and the second end, the middle region being axially offset from each of the first end and the second end.

7. The die carrier of claim 1, further comprising a shoe portion disposed on a bottom surface of each of the first end and the second end.

8. The die carrier of claim 1, further comprising a locator plate disposed on a top surface of each of the first end and the second end.

9. A die cast assembly comprising: a die structured to form a molded part from a casting material; and a die carrier structured to support the die, the die carrier comprising: a first end and a second end opposite the first end, the first end being connected to the second end via a frame; and at least one hydraulic assembly disposed within the frame; wherein the hydraulic jack is structured to apply a first load to the die to prevent sagging of the die within the die cast assembly.

10. The die case assembly of claim 9, wherein the hydraulic jack is structured to apply the first load responsive to a second load applied to the die carrier.

11. The die cast assembly of claim 9, further comprising a first platen and a second platen, wherein the die is disposed between the first platen and the second platen.

12. The die cast assembly of claim 11, wherein the first platen is a moving platen and the second platen is a stationary platen.

13. The die cast assembly of claim 11, further comprising at least one sensor disposed on at least one of the first platen or the second platen, the at least one sensor configured to sense a third load applied to at least one of the first platen or the second platen.

14. The die cast assembly of claim 9, wherein the frame comprises a middle region disposed between the first end and the second end, the middle region being axially offset from each of the first end and the second end.

15. The die cast assembly of claim 9, wherein the casting material comprises magnesium.