AGRATI AEE with Bosch Rexroth, for Foundry Innovation and Energy Savings

Bosch Rexroth solutions can now be found on all the AGRATI AEE die-casting machines.

by Roberto Guccione

The need for research into technological progress and energy savings is fundamental for the foundry sector if it wants to remain competitive and acquire new business opportunities. Inspired by this need, AGRATI AEE has enhanced its die-casting machines with Bosch Rexroth technologies embodying the innovation required in this sector.
Founded in 1983 in Verdellino, in the province of Bergamo, AGRATI AEE can boast a solid, long-term presence in the markets for die-casting machines (both hot and cold chamber), collaborating with the most prestigious customers and partners. Today, the company has a turnover of around 8 million euro per year and a total of 25 employees. Its range of machines for die-cast forming with aluminium and zinc alloys is used in a variety of fields from car manufacturing to furnishings and fashion, plus many others.
Distinguished right from the start by a spirit of entrepreneurship that stimulates the tendency to grow and progress, AGRATI AEE has taken full advantage of the opportunity offered by Bosch Rexroth to create a new range of products for the foundry sector, to meet one of the essential needs of the market – products that can ensure a notable reduction in energy consumption.

Energy and water saving
Thanks to its collaboration with Bosch Rexroth, launched between late 2008 and early 2009, the company has in fact been able to optimise what started out as a standard product. The result is a new line of machines of higher quality and bearing the “ENERGY SAVING” label, replacing the previous models. The old asynchronous motors have been replaced with brushless ones that guarantee lower consumption plus the possibility of discontinuous operation with variable power levels optimised in relation to the machine cycle phase. Gear pumps have taken the place of the previous paddle pumps to offer greater durability, and machine adjustment is now proportional rather than ON-OFF. The new AGRATI AEE machines use Sytronix SVP7000 to develop functions and hydraulic adjustments with the greatest ease. In addition, Bosch Rexroth has enhanced the drive firmware with an “on demand” control function for the energy required for machine movements. This reduces energy consumption in the plant by up to 80% because it can minimise the absorption level in the moment when no energy is being used by plant parts, whilst always guaranteeing a prompt reaction to sudden power requests from the machine. Thanks to these solutions, energy savings of 60% to 80% (depending on the type of machine in question) have been obtained, not to mention a notable reduction in the amount of cooling water needed for the machine.
The implementation of these innovations hinges on the partnership with Bosch Rexroth who, apart from suggesting a series of solutions with the best power levels for AGRATI AEE products, also improved the adaptability of existing projects. Bosch Rexroth showed constant commitment, from the design phase through to the end product, offering technical advice and subsequently sustaining AGRATI AEE in the development and aftersale stages as well. An all-round partner that assisted the company throughout all the steps of the project – roughly 2 months for development and a further 4 for implementation.
Bosch Rexroth solutions can now be found on all the AGRATI AEE machines, both hot chamber versions and cold. For the future, the company envisages the use of these technologies on machines of greater tonnage too.