Hydraulic System

Pressure Sensors → Track injection and clamping pressures for consistency.

Flow Sensors → Monitor oil flow to actuators and cooling circuits.

Temperature Sensors → Detect overheating of hydraulic oil.

Vibration Sensors → Identify early pump or valve wear.

Die & Mold Conditions

Thermocouples / Infrared Sensors → Measure die surface temperature to maintain optimal fill and cooling.

Cooling Line Flow & Temperature Sensors → Ensure proper thermal management of the mold.

Position Sensors → Confirm die open/close, ejector stroke.

Injection System

Linear Position Sensors (LVDT / Magnetostrictive) → Track piston stroke and shot speed.

Pressure Transducers → Monitor metal injection pressure.

Speed/RPM Sensors → Verify injection plunger speed profiles.

Molten Metal Handling

Level Sensors → Maintain consistent molten aluminum level in holding furnace.

Temperature Sensors → Monitor melt temperature before injection.

Gas / Oxygen Sensors → Ensure furnace atmosphere safety.

Clamping System

Load Cells / Strain Gauges → Measure clamping force to avoid flashing and tool wear.

Displacement Sensors → Confirm correct alignment and movement of platens.

Machine Health

Vibration Sensors → Detect bearing or gearbox issues.

Current & Power Sensors → Monitor motor efficiency and detect abnormal loads.

Lubrication Monitoring (Oil Quality / Particle Sensors) → Predict wear in hydraulic and mechanical systems.

Environmental & Safety

Ambient Temperature / Humidity Sensors → Track casting cell environment.

Gas / Air Quality Sensors → Detect emissions, leaks, or smoke.

Proximity & Safety Sensors → Ensure guarding and operator safety compliance.