In modern manufacturing industry, die-casting machine as an important precision equipment, widely used in automotive, electronics, home appliances and other industries. It can efficiently produce metal parts with complex shapes and high precision requirements. However, due to the long-term high-intensity operation and complex working environment, die casting machines are prone to various failures, resulting in stagnation of the production line, affecting production efficiency and enterprise economic benefits. Therefore, taking effective measures to prevent die-casting machine failure and reduce production downtime is crucial to ensure the continuity of production and improve the competitiveness of enterprises.

1、 Die casting machine common failure and cause analysis

Mechanical failure: including hydraulic system failure, lubrication system failure, transmission system failure, etc. These failures are usually caused by wear, aging, or improper operation of parts.

Electrical failure: such as control system failure, sensor failure, etc. This kind of failure is often caused by electrical component damage or program errors.

Thermodynamic failure: Improper control of mold temperature during die casting may lead to a decline in casting quality and even damage to the mold.

Operation error: the irregular operation of the operator is also an important reason for the failure of the die casting machine.

2、Preventive measures and strategies

Regular maintenance and inspection: Develop a detailed die-casting machine maintenance plan, including daily inspection, weekly inspection, monthly inspection and annual inspection. Focus on checking the cleanliness of the hydraulic oil, the integrity of the lubrication system, the wear of the transmission components and the reliability of the electrical system. By regularly replacing worn parts, cleaning or replacing filters, many potential failures can be effectively avoided.

Optimize the operation process: Conduct professional training for the operators to ensure that they are familiar with the operating procedures and maintenance knowledge of the die casting machine. Emphasize the importance of proper use of equipment to avoid faults caused by improper operation. At the same time, establish standard operating procedures (Sops) to reduce human error.

Upgrading equipment: With the development of technology, the new die casting machine is more user-friendly in design and more stable in performance. For old equipment, you can consider upgrading technology or replacing new equipment to improve production efficiency and reliability.

Implementation of predictive maintenance: Using iot technology and big data analysis, real-time monitoring of the operating status of the die casting machine, analysis through the collected data, prediction of possible problems, and intervention before problems occur. This condition-based maintenance strategy can greatly reduce unplanned downtime.

Strengthen mold management: Mold is a key part of the die casting process, and its state directly affects product quality and machine life. Regular maintenance and overhaul of the mold to ensure uniform temperature distribution of the mold and avoid production interruption caused by mold problems.

Establish an emergency response mechanism: Even if all precautions are taken, failure cannot be completely avoided. Therefore, it is necessary to establish a fast and effective emergency response mechanism. This includes the management of spare parts inventory, the formation of maintenance teams and the operation process in case of emergency.

3、 Case analysis

By implementing the above preventive measures, an auto parts manufacturing company successfully reduced the failure rate of the die casting machine by 40% and the production downtime by 50%. This includes the introduction of advanced predictive maintenance systems to monitor critical components in real time; Strengthen the training and assessment of operators; Some of the old equipment has been updated, and the existing equipment has been upgraded. These measures not only improve production efficiency, but also significantly improve product quality and enhance the market competitiveness of enterprises.

4、 Conclusion

As an important equipment in manufacturing industry, the stable operation of die casting machine is of great significance to ensure production efficiency and product quality. By taking a series of preventive measures, such as regular maintenance, optimization of operational processes, technical upgrades, predictive maintenance, mold management and the establishment of emergency response mechanisms, die-casting machine failures can be effectively prevented and production downtime reduced. This not only helps to reduce maintenance costs, but also improves the market competitiveness of enterprises. In the future, with the continuous development of intelligent manufacturing technology, the intelligent level of die casting machine will be further improved, bringing greater economic benefits to enterprises.