Project Background and Core Process Requirements

As the die-casting industry demands higher energy efficiency and melt quality, WONDERY delivered the WDL-CDJ-5000 Vertical Immersion-type Holding Furnace. The client, specializing in high-precision die-casting, sought to overcome the low efficiency and high oxidation losses of traditional radiant heating. The core objectives were to achieve a precise control accuracy of ±2 ℃ and significantly reduce operational energy consumption.

Technical Solutions and Parameterized Evidence

1. Immersion Direct Heating Technology (Energy Savings >30%)

This system revolutionizes thermal transfer by placing heating elements directly into the molten aluminum:

• Thermal Efficiency: Heat is transferred directly from the inside out, preventing the formation of oxide skins. Compared to standard radiant furnaces, energy consumption is reduced by more than 30%.

• Core Components: Equipped with a 70kW SOCE immersion heating element paired with a Thai Silicon T6 series power regulator for linear and stable energy output.

2. Siemens Fully Automated Control System

To meet Industry 4.0 standards, WONDERY implemented a comprehensive Siemens control architecture:

• Hardware: Features a Siemens S7-200 SMART PLC and a SMART 71000 IE V5 touchscreen.

• Precision Monitoring: Integrates a Keyence LR-TB5000 laser rangefinder for non-contact liquid level monitoring and Siemens analog modules for real-time data acquisition.

• Control Accuracy: Achieves a verified melt temperature accuracy of ±2 ℃, ensuring consistent quality for high-end die-cast parts.

3. Patented Structure and Nano-Insulation

• Insulation Performance: The furnace top and upper walls are insulated with a heat-insulating nano-layer, ensuring minimal thermal loss.

• Surface Temperature: The furnace wall temperature rise is kept within 20 ℃ above ambient, significantly improving the safety and comfort of the workshop environment.

• Longevity: The patented structural design ensures a longer furnace lifespan even under continuous immersion in molten aluminum.

4. Efficient Maintenance and Consumables Management

• Easy Replacement: The immersion element design allows for convenient on-site replacement following basic training, minimizing production downtime.

• Spare Parts Strategy: WONDERY provided a recommended inventory of 4 thermocouples and 2 heating elements to safeguard continuous operation.

Delivery Specifications and Key Parameters

• Model: WDL-CDJ-5000 (Vertical insertion type).

• Heating Power: 70 kW.

• Key Components: Siemens automation suite, Keyence laser sensors, and nano-insulation technology.

• Support Documents: Includes full electrical schematics, installation drawings, and comprehensive technical protocols.