Method and system for die casting

Abstract

A method and system of casting. The system of casting including a mold, a water inlet, and an outlet valve. The mold including a mold fluid inlet and a mold fluid outlet. The water inlet being selectively fluidly coupled to the mold fluid inlet via a first valve. The mold fluid outlet being fluidly coupled to the outlet valve.

What is claimed is: 
     
         1 . A method of casting, the method comprising:
 determining a presence of or a non-presence of a leak within a mold of a casting system, the mold having a mold fluid inlet and a mold fluid outlet, the method of determining the presence of or non-presence of the leak comprising:
 closing an outlet valve provided downstream of and fluidly coupled to the mold fluid outlet; 
 after closing the outlet valve, opening a first valve to selectively fluidly couple a water inlet to the mold fluid inlet; 
 determining if a switch provided downstream of the first valve and upstream of the mold is opened or closed; 
 if the switch is closed, determining the presence of a leak within the mold; and 
 if the switch is opened, determining the non-presence of a leak within the mold. 
   
     
     
         2 . The method of  claim 1 , further comprising if the switch is closed:
 opening a second valve to selectively fluidly couple a gaseous fluid through a gas inlet to the mold fluid inlet;   closing the outlet valve;   supplying a gaseous fluid to the mold through the mold fluid inlet; and   purging water within the casting system through the leak in the mold.   
     
     
         3 . The method of  claim 1 , wherein the mold defines an interior housing a part, the method further comprising:
 spraying the part; and   determining the presence of or non-presence of the leak in tandem with, directly before, or directly after spraying.   
     
     
         4 . The method of  claim 3 , further comprising closing a mold if no leak is determined. 
     
     
         5 . The method of  claim 3 , further comprising terminating a casting of the part if the switch is closed. 
     
     
         6 . The method of  claim 1 , further comprising if the switch is closed, communicating a presence of the leak. 
     
     
         7 . The method of  claim 1 , further comprising:
 prior to opening the first valve, opening a third valve provided downstream the switch; and   after opening the first valve to fluidly couple the water inlet to the mold fluid inlet, closing the first valve.   
     
     
         8 . The method of  claim 1 , further comprising after closing the outlet valve, opening a first valve to selectively fluidly couple the water inlet to a first branch selectively fluidly coupled to the mold fluid inlet and a second branch electively fluidly coupled to the mold fluid inlet and including the switch. 
     
     
         9 . The method of  claim 1 , further comprising:
 automatically closing, via a controller module of the casting system, the outlet valve;   after closing the outlet valve, automatically opening, via the controller module, the first valve; and   automatically determining, via the controller module, if the switch is opened or closed.   
     
     
         10 . A casting system comprising:
 a mold having a mold fluid inlet and a mold fluid outlet;   a water inlet selectively fluidly coupled to the mold fluid inlet through a first valve;   an outlet valve provided downstream of and fluidly coupled to the mold fluid outlet;   a switch provided downstream of the first valve and being selectively fluidly coupled to the mold fluid inlet, the switch being movable between an opened position and a closed position; and   a controller module configured to detect a presence of or a non-presence of a leak within the mold by:
 closing the outlet valve; 
 after closing the outlet valve, opening the first valve to direct a water from the water inlet into the mold through the mold fluid inlet; 
 determining if the switch is opened or closed; 
 if the switch is closed, determining the presence of a leak within the mold; and 
 if the switch is opened, determining the non-presence of a leak within the mold. 
   
     
     
         11 . The casting system of  claim 10 , further comprising:
 a first branch fluidly coupling the first valve to the mold fluid inlet; and   a second branch fluidly coupling the first valve to the mold fluid inlet, the first branch and the second branch meeting at a junction downstream of the first valve, the second branch including the switch.   
     
     
         12 . The casting system of  claim 11 , further comprising a second valve provided downstream of the junction. 
     
     
         13 . The casting system of  claim 10 , further comprising a first check valve provided on the first branch and a second check valve provided on the second branch, upstream of the switch. 
     
     
         14 . The casting system of  claim 10 , further comprising a gas inlet selectively fluidly coupled to the mold fluid inlet. 
     
     
         15 . The casting system of  claim 14 , wherein if the leak is detected, the controller module is configured to:
 open a second valve to selectively fluidly couple a gaseous fluid through a gas inlet to the mold fluid inlet;
 close the outlet valve; 
 supply a gaseous fluid to the mold through the mold fluid inlet; and 
 purge the water within the casting system through the leak in the mold. 
   
     
     
         16 . A method of casting, the method comprising:
 injecting a molten metal into a mold, the mold having a mold fluid inlet and a mold fluid outlet;   impacting the mold; and   directly before, in tandem with, or directly after impacting the mold:
 opening a first valve to selectively fluidly couple a water inlet to the mold through the mold fluid inlet in order to cool the molten metal within the mold; 
 after opening the first valve, performing a gaseous fluid purge by:
 closing the first valve; and 
 after closing the first valve, opening a second valve to selectively fluidly couple a gas to the mold through the mold fluid inlet; and 
 
   impacting the mold once the gaseous fluid purge is completed.   
     
     
         17 . The method of  claim 16 , further comprising:
 prior to closing the first valve, determining a heat of the mold by measuring a temperature of a fluid within the mold fluid inlet, and   closing the first valve once the measured temperature is lower than a threshold temperature.   
     
     
         18 . The method of  claim 16 , further comprising:
 determining if the gaseous fluid purge is desired;   performing the gaseous fluid purge only if the gaseous fluid purge is desired; and   if the gaseous fluid purge is not desired, closing the first valve and subsequently impacting the mold.   
     
     
         19 . The method of  claim 16 , further comprising ejecting a fluid from a leak within the mold during the gaseous fluid purge. 
     
     
         20 . The method of  claim 16 , further comprising opening, via a controller module, the first valve;
 after opening the first valve, performing, via the controller module, the gaseous fluid purge by:
 closing, via the controller module, the first valve; and 
 opening, via the controller module, the second valve.