Carat.: High Value Creation For Sophisticated Parts
Carat.: High Value Creation For Sophisticated Parts
Carat.: High Value Creation For Sophisticated Parts
High value
creation for
sophisticated
parts.
Carat is the two-platen die-casting solution with a locking force from 10,500 to
61,000 kN. The system was designed specifically for manufacturing large and
complex parts such as structural components, which need to meet the highest
quality requirements. Flexibly-designed Carat technology enables you to precisely
adjust the die-casting process to fit your manufactured components and their
properties.
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6
6
SmartCMS – Your operator in total control.
–– View, control and program your entire die-casting cell from one centralized
user interface
–– Paving the way for extensive improvements and advantages at the cell level
–– Future connection of your cell with Industry 4.0 smart factory systems and
our Digital Services
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Carat.
High Value Creation.
1 2
Higher efficiency through Technology for the best
two-platen technology. casting results.
–– Stable production processes due to compact –– Bühler’s unique SC (shot control)
design and high rigidity systems enable every die-casting
–– Improved locking force distribution for reduced process to be controlled in real-time
flash –– Reproducible casting results
–– Ability to cast larger sized products within the –– Creates a controlled, stable process
same floor space that preserves the die
3
30 % additional shot
capacity for reliable
production.
–– Powerful injection unit
5 –– High dynamics for improved die filling
–– Power reserves to compensate for
process fluctuations and aid stable
4 production
4
5 Intuitive DataView
machine control.
Significantly improved energy
efficiency. –– Intuitive and user-friendly control system
for up to 25 % shorter programming time
–– Reduction of energy consumption by over 20 % –– Integrated process and system
using optional control technology diagnostics
–– Optional servo drive system reduces energy –– Interactive real-time control of the die-
consumption by up to 40 % casting machine
3
Carat.
High Value Creation.
up to
4
Carat.
High Value Creation.
up to
5
Carat.
High Value Creation.
Tailored service.
To be successful, you require a stable manufacturing process.
Our service team can support you from the initial idea and the
planning of your production, up to training, consulting and the
reconditioning of your equipment. You can also benefit from our
service contracts, tailored to your needs.
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7
Carat.
High Value Creation.
By thinking of the cell as one system, rather than a machine equipped with a lot of
peripherals, SmartCMS gives the operator the possibility to view, control and program
the entire cell from one centralized user interface.
For a number of years now, Bühler die-casting machines production changes, lower diagnostic time and effort can
have offered more and more digital control options to give enhance efficiency and improve your cell OEE.
your operators better visibility of the machine.
For future integration with Industry 4.0 smart factory systems
SmartCMS is now expanding the digital control to the entire and Bühler Digital Services, Carat is ready for SmartCMS for
die-casting cell. The Bühler FlexInterface with standardized centralized operation and new data management
protocol enables the basis for connectivity between the cell possibilities.
controller and the peripheral devices for extended information
and data exchange.
8
Carat.
High Value Creation.
The myBühler customer portal offers you easy access to all details of your
Bühler equipment and helps you do easy business with us.
Bühler Insights
eService eMaintenance
eCommerce eTraining
Product Information
With a single sign on you will have access to the following services:
–– Product information –– eService
–– eCommerce –– eTraining
–– eMaintenance –– Bühler Insights
The myBühler customer portal is also the entering point to all of our digital services.
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Carat.
High Value Creation.
SmartVac.
Vacuum system with higher
process transparency.
Our SmartVac vacuum system is integrated seamlessly into the vacuum level and the evacuation level individually. In
the Carat die-casting machine. It is controlled centrally with the addition, cyclical tests allow you to quickly evaluate the current
DataView control unit. All relevant vacuum parameters are filter condition, informing proactive maintenance decisions.
measured, monitored and assigned to the process directly –
SmartVac is equipped with monitoring of chill vents, hydraulic
giving you comprehensive process transparency and optimum
or electric die valves, profile monitoring per evacuation
quality of the components you are making.
channel, and centralized alarm handling. SmartVac can be
SmartVac allows the use of many commercially available equipped with the following options: Controlling / monitoring
vacuum valves. You can monitor and control up to four of mechanic die valves, shot sleeve evacuation unit, die
evacuation points on the die and one on the shot sleeve evacuation units, ejector box evacuation unit and larger
independently of one another, simultaneously. You can adjust vacuum pump.
Technical data.
400/100 500/100 600/160 750/200 1000/250 1500/320 2000/400
Volumetric capacity of the vacuum tank l 400 500 600 750 1000 1500 2000
Vacuum pump (Busch) m³/h 100 100 160 200 250 2*160 2*200
Monitored die evacuation channels max. 4 max. 4 max. 4 max. 4 max. 4 max. 4 max. 4
Suitable for Carat 105 130 – 140 160 – 180 200 – 220 250 – 280 320 – 350 400 – 440
10
Carat.
High Value Creation.
BuhlMark.
Permanent marking for
complete traceability.
You can integrate our BuhlMark marking device to apply protected stamping unit, which ensures extremely low
alphanumeric characters and codes in three different stamping maintenance.
types.
You can program marking codes directly on the control unit,
The quick and permanent marking ensures unique and and save them as part of your die program. This enables error-
constant traceability. BuhlMark is specially optimized for use in free and quick change of your dies and ensures that all data is
the harsh conditions in your foundry and features a completely centrally available.
Technical data.
Font height
in mm SH 1.8 SH 2 SH 2.5 SH 3 SH 4 SH 5 SH 6 SH 7
Figure set A B C A B C A B C A B C A B C A B C A B C A B C
2 figures 0.4 0.4 0.7 0.4 0.4 0.8 0.5 0.5 0.9 0.6 0.6 0.9 0.7 0.7 1.1 0.8 0.8 1.1 0.9 0.9 1.2 1.0 1.1 1.3
10 figures 2.0 1.8 3.3 2.1 1.8 3.4 2.4 2.1 3.8 2.6 2.4 4.0 3.1 2.9 4.5 3.6 3.4 4.9 4.0 3.9 5.3 4.5 4.3 5.7
40 figures single-spaced 7.8 6.9 12.9 8.2 7.4 13.6 9.3 8.4 14.8 10.3 9.4 15.9 12.0 11.1 17.7 13.1 12.4 18.7 14.4 13.7 19.7 15.6 14.9 20.6
Max. figures per second 5.15 5.77 3.09 4.86 5.44 2.93 4.30 4.76 2.69 3.87 4.25 2.52 3.32 3.60 2.26 3.05 3.22 2.14 2.77 2.93 2.03 2.57 2.68 1.94
Code size
in mm 6 × 6 9 × 9 10 × 10 12 × 12 15 × 15 20 × 20
Embossing mode Bi Bi Bi Bi Bi Bi
* All descriptions are purely marking times – in-feed movements of the marking unit or marking heads as well as intermediate movements and movements towards the marking position
or return to Home Position are not included. The marking times are reference values. Binding time specifications are only made by marking trial with an original workpiece. The
marking speed can have a significant impact on the marking. The quality of the marking depends also on the built-in situation, rigidity of the marking unit parts (please notice our
installation instructions), marking position, workpiece geometry and surface of the workpiece.
** All times stated are pure marking times, exclusive of feed travel of the marking unit or marking head or of detour travel and lengthy travel to the marking point.
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Carat.
High Value Creation.
BuhlRob.
Reliable and fast extraction of parts.
Our BuhlRob robot is specifically designed for part removal in Additionally, the device is integrated into your die-casting
your foundry. The system is based on the proven ABB or system control unit, which gives you graphical visualization of
KUKA technologies. BuhlRob distinguishes itself through its the robot’s functions. This allows all data to be clearly available
compact design, its high range and a high working load. and simplifies handling for your operator.
Technical data.
Handling weight (gripper and load) kg 40 Handling weight (gripper and load) kg 205
Interference contour robot (no gripper mm 400 Interference contour robot (no gripper mm 650
and load) (radius) and load) (radius)
Dimensions of control cabinet (LWH) mm 725 × 710 × 970 (1370) Dimensions of control cabinet (LWH) mm 725 × 710 × 970 (1370)
Suitable for Carat under certain conditions – Suitable for Carat under certain conditions 160 – 180
Handling weight (gripper and load) kg 150 Handling weight (gripper and load) kg 150
Interference contour robot (no gripper mm 650 Interference contour robot (no gripper mm 700
and load) (radius) and load) (radius)
Dimensions of control cabinet (LWH) mm 725 × 710 × 970 (1370) Dimensions of control cabinet (LWH) mm 725 × 710 × 970 (1370)
Suitable for Carat under certain conditions 160 – 280 Suitable for Carat under certain conditions –
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Carat.
High Value Creation.
BuhlLadle.
Precise and consistent dosing.
BuhlLadle gives you precise and consistent dosing of liquid The servo technology enables you to program precise speeds
aluminum. Featuring a robust design and simple handling, it is and ladle angles to suit each component. Extraordinary
entirely integrated into the control unit of your die-casting positioning accuracy can increase your dosing consistency
system. and reduce cycle times.
Technical data.
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Carat.
High Value Creation.
BuhlSpray.
Efficient spraying.
BuhlSpray is a two-axis spraying device and offered in three structure contributes to a high level of availability for your die-
expansion stages. With tools for up to eight spraying and casting cell. BuhlSpray can be integrated seamlessly into your
blowing cycles, the device will provide even coverage for die-casting system’s control unit, helping to provide simpler
products with the most intricate cavities. It features a Flextool handling and quicker changing of dies.
spray head and an AC-Servo drive. The robust design
Technical data.
Vertical Horizontal Number Number of No. of high- Connected Dimensions of Weight of Suitable for Suitable for
stroke stroke of spray- die pressure power sprayer (LxWxH) die spray Carat Carat under
blow release blow unit certain
circuits agents circuits conditions
mm mm kW mm kg
Model 2M 6/2
V2000 H1600 2000 1600 6 2 2 11 2684 × 1332 × 3200 1150 105 – 140 160 – 180
Model 3M 8/4
V1800 H1600 1800 1600 8 4 2 22 2968 × 1350 × 3233 1700 160 – 180 105 – 140
Model 3M 8/4
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Carat.
High Value Creation.
Carat.
Technical data / dimensions.
Injection unit.
Projected Specific
Injection force, Injection Plunger Shot weight (Al) area, plunger Projected injection
dynamic force, diameter Shot Plunger (min. / max.) diameter area at pressure
Machine type (90 % injection stroke) intensified (min. / max.) position stroke filling rate 60% (min. / max.) 400 bar (min. / max.)
105 lean 288 760 70 / 120 − 50 / − 350 700 3.6 / 10.7 532 / 1563 2625 672 / 1975
105 compact 409 1096 80 / 140 0 / − 350 850 5.8 / 17.7 482 / 1475 2625 712 / 2180
105 extended 583 1530 100 / 160 0 / − 350 1050 11.1 / 28.5 539 / 1380 2625 761 / 1948
130 lean 288 760 70 / 120 − 50 / − 350 700 3.6 / 10.7 658 / 1935 3250 672 / 1975
130 compact 409 1096 80 / 140 0 / − 350 850 5.8 / 17.7 596 / 1826 3250 712 / 2180
130 extended 583 1530 100 / 160 0 / − 350 1050 11.1 / 28.5 667 / 1708 3250 761 / 1948
140 lean 288 760 70 / 120 − 50 / − 350 700 3.6 / 10.7 709 / 2083 3500 672 / 1975
140 compact 409 1096 80 / 140 0 / − 350 850 5.8 / 17.7 642 / 1966 3500 712 / 2180
140 extended 583 1530 100 / 160 0 / − 350 1050 11.1 / 28.5 719 / 1840 3500 761 / 1948
160 lean 409 1096 80 / 140 −70 / − 420 850 5.8 / 17.7 734 / 2247 4000 712 / 2180
160 compact 583 1530 100 / 160 0 / − 420 1050 11.1 / 28.5 821 / 2103 4000 761 / 1948
160 extended 814 2076 120 / 180 0 / − 420 1300 19.8 / 44.7 872 / 1961 4000 816 / 1836
180 lean 409 1096 80 / 140 −70 / − 420 850 5.8 / 17.7 807 / 2472 4400 712 / 2180
180 compact 583 1530 100 / 160 0 / − 420 1050 11.1 / 28.5 903 / 2313 4400 761 / 1948
180 extended 814 2076 120 / 180 0 / − 420 1300 19.8 / 44.7 959 / 2157 4400 816 / 1836
200 lean 409 1096 80 / 140 −70 / − 420 850 5.8 / 17.7 917 / 2809 5000 712 / 2180
200 compact 583 1530 100 / 160 0 / − 420 1050 11.1 / 28.5 1027 / 2628 5000 761 / 1948
200 extended 814 2076 120 / 180 0 / − 420 1300 19.8 / 44.7 1090 / 2452 5000 816 / 1836
220 lean 409 1096 80 / 140 −70 / − 420 850 5.8 / 17.7 1009 / 3090 5500 712 / 2180
220 compact 583 1530 100 / 160 0 / − 420 1050 11.1 / 28.5 1129 / 2891 5500 761 / 1948
220 extended 814 2076 120 / 180 0 / − 420 1300 19.8 / 44.7 1199 / 2697 5500 816 / 1836
250 lean 583 1530 100 / 160 −70 / − 490 1050 11.1 / 28.5 1283 / 3285 6250 761 / 1948
250 compact 814 2076 120 / 180 0 / − 560 1300 19.8 / 44.7 1362 / 3064 6250 816 / 1836
250 extended 1165 2792 135 / 200 0 / − 560 1400 27.1 / 59.4 1282 / 2813 6250 889 / 1951
280 lean 583 1530 100 / 160 −70 / − 490 1050 11.1 / 28.5 1412 / 3614 6875 761 / 1948
280 compact 814 2076 120 / 180 0 / − 560 1300 19.8 / 44.7 1498 / 3371 6875 816 / 1836
280 extended 1165 2792 135 / 200 0 / − 560 1400 27.1 / 59.4 1410 / 3094 6875 889 / 1951
320 lean 583 1530 100 / 160 −70 / − 490 1050 11.1 / 28.5 1643 / 4205 8000 761 / 1948
320 compact 814 2076 120 / 180 0 / − 560 1300 19.8 / 44.7 1743 / 3922 8000 816 / 1836
320 extended 1165 2792 135 / 200 0 / − 560 1400 27.1 / 59.4 1641 / 3601 8000 889 / 1951
350 lean 583 1530 100 / 160 −70 / − 490 1050 11.1 / 28.5 1797 / 4599 8750 761 / 1948
350 compact 814 2076 120 / 180 0 / − 560 1300 19.8 / 44.7 1907 / 4290 8750 816 / 1836
350 extended 1165 2792 135 / 200 0 / − 560 1400 27.1 / 59.4 1794 / 3938 8750 889 / 1951
400 lean 814 2076 120 / 180 − 40 / − 600 1300 19.8 / 44.7 2179 / 4903 10 000 816 / 1836
400 compact 1165 2792 135 / 200 0 / − 600 1400 27.1 / 59.4 2051 / 4501 10 000 889 / 1951
440 lean 814 2076 120 / 180 − 40 / − 600 1300 19.8 / 44.7 2397 / 5393 11 000 816 / 1836
440 compact 1165 2792 135 / 200 0 / − 600 1400 27.1 / 59.4 2256 / 4951 11 000 889 / 1951
560 1165 2792 135 / 240 − 100 / −700 1400 27.1 / 105.3 2871 / 9074 14 000 617 / 1951
610 1165 2792 135 / 240 − 100 / −700 1400 27.1 / 105.3 3127 / 9884 15 250 617 / 1951
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Carat.
High Value Creation.
Closing unit.
kN mm mm mm mm kN mm kg m
10 500 1600 × 1600 1000 × 1000 562 / 1150 1000 400 220 49 500 8.5 × 3.8 × 3.8
10 500 1600 × 1600 1000 × 1000 562 / 1150 1000 400 220 51 000 9.0 × 3.8 × 4.0
10 500 1600 × 1600 1000 × 1000 562 / 1150 1000 400 220 53 000 9.7 × 3.8 × 4.3
13 000 1780 × 1780 1100 × 1100 640 / 1300 1100 400 220 58 000 8.9 × 4.0 × 3.9
13 000 1780 × 1780 1100 × 1100 640 / 1300 1100 400 220 60 000 9.5 × 4.0 × 4.1
13 000 1780 × 1780 1100 × 1100 640 / 1300 1100 400 220 63 000 10.1 × 4.0 × 4.4
14 000 1780 × 1780 1100 × 1100 640 / 1300 1100 400 220 58 000 8.9 × 4.0 × 3.9
14 000 1780 × 1780 1100 × 1100 640 / 1300 1100 400 220 60 000 9.5 × 4.0 × 4.1
14 000 1780 × 1780 1100 × 1100 640 / 1300 1100 400 220 63 000 10.1 × 4.0 × 4.4
16 000 2000 × 2000 1250 × 1250 724 / 1450 1250 500 240 85 000 10.3 × 4.3 × 4.1
16 000 2000 × 2000 1250 × 1250 724 / 1450 1250 500 240 87 000 11.0 × 4.3 × 4.5
16 000 2000 × 2000 1250 × 1250 724 / 1450 1250 500 240 89 000 11.9 × 4.3 × 4.5
17 600 2000 × 2000 1250 × 1250 724 / 1450 1250 500 240 85 000 10.3 × 4.3 × 4.1
17 600 2000 × 2000 1250 × 1250 724 / 1450 1250 500 240 87 000 11.0 × 4.3 × 4.5
17 600 2000 × 2000 1250 × 1250 724 / 1450 1250 500 240 89 000 11.9 × 4.3 × 4.5
20 000 2240 × 2240 1400 × 1400 772 / 1600 1400 500 240 128 000 11.0 × 4.5 × 4.3
20 000 2240 × 2240 1400 × 1400 772 / 1600 1400 500 240 130 000 11.6 × 4.5 × 4.7
20 000 2240 × 2240 1400 × 1400 772 / 1600 1400 500 240 133 000 12.5 × 4.5 × 4.7
22 000 2240 × 2240 1400 × 1400 772 / 1600 1400 500 240 128 000 11.0 × 4.5 × 4.3
22 000 2240 × 2240 1400 × 1400 772 / 1600 1400 500 240 130 000 11.6 × 4.5 × 4.7
22 000 2240 × 2240 1400 × 1400 772 / 1600 1400 500 240 135 000 12.5 × 4.5 × 4.7
25 000 2480 × 2480 1550 × 1550 880 / 1800 1550 680 280 155 000 12.6 × 4.9 × 4.8
25 000 2480 × 2480 1550 × 1550 880 / 1800 1550 680 280 158 000 13.5 × 4.9 × 4.9
25 000 2480 × 2480 1550 × 1550 880 / 1800 1550 680 280 162 000 13.7 × 4.9 × 5.0
27 500 2480 × 2480 1550 × 1550 880 / 1800 1550 680 280 155 000 12.6 × 4.9 × 4.8
27 500 2480 × 2480 1550 × 1550 880 / 1800 1550 680 280 158 000 13.5 × 4.9 × 4.9
27 500 2480 × 2480 1550 × 1550 880 / 1800 1550 680 280 162 000 13.7 × 4.9 × 5.0
32 000 2750 × 2750 1700 × 1700 988 / 2000 1700 680 280 205 000 13.3 × 5.3 × 4.9
32 000 2750 × 2750 1700 × 1700 988 / 2000 1700 680 280 209 000 14.2 × 5.3 × 5.0
32 000 2750 × 2750 1700 × 1700 988 / 2000 1700 680 280 214 000 14.4 × 5.3 × 5.1
35 000 2750 × 2750 1700 × 1700 988 / 2000 1700 680 280 205 000 13.3 × 5.3 × 4.9
35 000 2750 × 2750 1700 × 1700 988 / 2000 1700 680 280 209 000 14.2 × 5.3 × 5.0
35 000 2750 × 2750 1700 × 1700 988 / 2000 1700 680 280 214 000 14.4 × 5.3 × 5.1
40 000 2970 × 2970 1800 × 1800 1044 / 2100 1800 1000 280 269 000 14.9 × 5.7 × 5.2
40 000 2970 × 2970 1800 × 1800 1044 / 2100 1800 1000 280 273 000 15.1 × 5.7 × 5.3
44 000 2970 × 2970 1800 × 1800 1044 / 2100 1800 1000 280 269 000 14.9 × 5.7 × 5.2
44 000 2970 × 2970 1800 × 1800 1044 / 2100 1800 1000 280 273 000 15.1 × 5.7 × 5.3
56 000 3580 x 3580 2200 x 2200 1300 / 2400 2200 1200 300 400 000 17.2 x 3.5 x 5.2
61 000 3580 x 3580 2200 x 2200 1300 / 2400 2200 1200 300 400 000 17.2 x 3.5 x 5.2
Subject to change without notice.
17
Carat.
High Value Creation.
Carat.
Technical data / dimensions.
Machine MA MB MC MD ME MF MG MH MI MJ MJ MK ML MN MO MP MQ
type* min. max.
105 1375 3670 440 9047 2900 1401 1920 1922 1940 1590 1940 3965 847 3204 1601 1374 6895
130 1565 3920 480 9487 2900 1401 2020 2022 2042 1692 2042 4067 847 3398 1729 1444 7593
140 1565 3920 480 9487 2900 1401 2020 2022 2042 1692 2042 4067 847 3398 1729 1444 7593
160 1410 4845 525 11 037 3035 1302 2170 2172 2200 1780 2200 4556 856 3696 1861 1815 8576
180 1410 4845 525 11 037 3035 1302 2170 2172 2200 1780 2200 4556 856 3696 1861 1815 8576
200 2030 4845 580 11 657 3035 1302 2270 2100 2340 1920 2340 4696 856 3975 1999 1945 9418
220 2030 4845 580 11 657 3035 1302 2270 2100 2340 1920 2340 4696 856 3975 1999 1945 9418
250 1725 6005 640 13 498 3191 1260 2470 2300 2526 1966 2526 4872 882 4386 2139 1910 10 603
280 1725 6005 640 13 498 3191 1260 2470 2300 2526 1966 2526 4872 882 4386 2139 1910 10 603
320 2405 6005 725 14 178 3191 1260 2670 2500 2696 2136 2696 5002 882 4718 2302 2045 11 619
350 2405 6005 725 14 178 3191 1260 2670 2500 2696 2136 2696 5002 882 4718 2302 2045 11 619
400 2405 6595 790 15 110 3359 1226 2870 2700 2876 2276 2876 5219 910 5033 2436 2180 12 470
440 2405 6595 790 15 110 3359 1226 2870 2700 2876 2276 2876 5219 910 5033 2436 2180 12 470
560 2384 7890 955 17 499 3359 1226 3470 3470 3283 2650 3250 5832 1050 5902 2800 2500 12 283
610 2384 7890 955 17 499 3359 1226 3470 3470 3283 2650 3250 5832 1050 5902 2800 2500 12 283
Units in mm
* Data based on type Carat compact Subject to change without notice.
MQ MC MP MO
MK
MJ min/max
MN
MI
ML
MA MB MF
MD ME
MG
MH
MG
MH
18
Bühler Carat –
the solution
tailored to your
part and your
individual
requirements.
en 0619 Z&B
Bühler AG
CH-9240 Uzwil
Switzerland
T +41 71 955 11 11
F +41 71 955 25 88
die-casting@buhlergroup.com
buhlergroup.com/die-casting