Advantages of the technique of casting/die steel strip cutting lines

Moulding plastic warmed by emboli of pre-shaped powered by servo motor and stamping piece moulded into the moulding station at the same time, allow to manufacture parts molded virtually no movement of the die, ensuring the accuracy of stamping that requires the user. New programmes of moulding and the optimized disposition of units involved in the process of casting allow to manufacture castings of geometries complicated with moulding by compressed air or vacuum by Illig, represented in Spain by Helmut Roegele.

Figures 1: Automatic machine for molding/die RDK 80, useful for molding/die with trim lines with strapping of steel and examples of products

The optimization of the processes to the termoconformar takes into account the operation combined machine and useful, which guarantees a production without problems, especially with work intervals shorts and a high degree of automation. The available components, such as: unit to cut holes, punch of strapping of steel and stacking system variants allow universal use of the machines can be used at the same time format games for molding and stamping separately. In combination with a perfected technique of fast tool change this allows high productivity, which also helps the reproducibility of all parameters of the process.

In its basic version the machines are equipped with heating top and bottom, making it possible to process materials such as the PS, PVC, APET, PAHO, PE and PP in thicknesses of 180 µm to 2.5 mm.

The RDK machines mark patterns by their manageability both its mechanical construction. The consistent use of dynamic servo motors with the most modern technology of control and regulation guarantees an exact adjustment of routes and speeds, allowing also an adjustment of basic data of the machine computer-aided. This becomes a reality greater availability, an increase in performance and improvements in the quality of the product.

Molding/stamping station is equipped with a mobile table top and a bottom. The open-end levers, the tables and the columnas-guía for a maximum force of stamping has been optimized for optimal results of court. Necessary closing and stamping force brings to tables through double open-end levers and servo motor with pinion moved by thread. So not form transverse forces in molding tables column guides, the force is centrally introduced by the articulation of the double bent lever. The speed profile designed with accuracy of double bent lever allows you to enter the maximum force during the process of stamping.

Figure 2: Station of molding/stamping RDK 80

With the various possibilities of adjustment for the tours of the tables and in tune with the tensors frameworks upper and lower speeds, operated separately, 14 of moulding different programs, all variations of molded part being achievable without problems are possible.

Thanks to the technique of the servodrive employed by ILLIG, with which it is possible to coordinate with great precision the movements of the table of molding with the piston of pre-shaped, an optimal distribution of the thickness of the side walls of the product can achieve. This better distribution of material allows also the same stability of the product for a lower thickness of plastic of departure. This leads to a qualitative product improvement, as for example a greater rigidity of the molded part and a few edges from sealed completely accurate and flat across the surface of seal, that are obtained by costumed chilled in the mold.

The direct provision of vacuum valves and air compressed molding station allows very short filling times for each of the cavities and thus very short cycle times. The molding can take place, choice, at the top table and at the bottom by vacuum or compressed air. To pre-select the program of moulding in the control panel are automatically performed all the required settings.

An important detail for the processing of the PP is the expansion device for transporting plastic. Through this device plastic transport pneumatically splits in the area of moulding station, was tense the plastic and prevents this way that wrinkles are formed in the moulding process. The necessary expansion value is obtained from thermal expansion of the plastic.

Four rows of resistance on the side of entry can disconnect to adjust heating upper and the lower to the passage of the transport. Thus compensates the influences of temperature of the mold for molding and cooling of the tensor framework, and avoid the marks of cooling on the side walls of the products. On the top and bottom heating, each of the rows of resistance is regulated through pilot resistance. Depending on the transport and the width of the plastic step are automatically disconnected the rows of resistance that may not be necessary. Other sequences of movements, such as aid of anti-corrosion for castings with carvings of stacking or a command of spare parts system, help to manufacture parts molded with very strong carvings.

Figure 3: Station of stacking standard for stacking cups. The additional troqueladora is not used in the manufacture of vessels.

The technique of processes and applications, along with extensive knowledge of materials, give rise to an optimal program of the machine, which includes the parameters to the moulding, cutting and stacking. Multiple machine movements meet centrally to make handling easy. Along with the servomotorizados drives mostly used, a calculation of optimum process times according to the plastic, the geometry of the molded part and the construction of the cutter and data adjustment can be done by the basic adjustment to new useful computer-aided. Optimized data can be stored and are available immediately in the event of repetition of the product. You can store up to 9999 data sets. To control the manufacture in progress you can access is permanently the main service data.

In the station of stacking the castings are separated from the tape of moulding by a piston of detachment and are transferred to the portaventosas of the Manipulator System Board. It works with two linear units and puts the pieces molded on a conveyor. Optionally a tape of download game two which facilitates taking products through the additional of molding, especially interesting role in case management of multiple machines can be used. Flexible and simple attachment of the tool also allows short time to re-equip for another product. It is helpful to the user handling parts use of stacking conventional.

The molded parts, e.g. bases for chocolates and biscuits, are not engaged in the stack and can desapilarse without problems, used the alternate stacking.

In the case of supplies of moulding of several rows, the buttons of stacking can be different and be prepared in several ways. In the station of stacking rows of products that are each along with others are pushed on each other and they are stacked in a single row (stacking a-B). The position of the buttons of stacking, that varies according to each molded piece, it maintains separate pieces.

Figure 5: Stack of pieces molded with stacking standard station

Before you start the production of a new order is required for the preparatory process. However, this cannot be confined only to a rapid change of the molding/stamping tool. In the conversion process should include all the pieces of format change. Only thus will the real time of inactivity be comparable. RDK machines, all the pieces of format can be changed by the side of management in order to achieve very short changeover times. The re-equipment program helps change the cutter, i.e. plastic transport automatically opens and then adjusts to the new width of the plastic. In addition, die cutting and stacking stations are carried the correct position on the moulding station. Stored data from previous orders or the basic adjustment in the case of new useful computer-aided are of great help in this. Moulding air supply lines and empty connect without thread to assemble the workpiece.

In addition to the conventional technique of fast tool change it is possible to change mold inserts and funds without removing the top of the mold. Format of the lower part of the useful parts are changed on a device for the purpose.

The modular construction of the machines RDK allows you to use the most various techniques of processes for moulding, cutting and stacking the products, which can be supplemented by a crusher mill for cutting of sheet. An intermediate frame where to use these devices is used for placement of bases of suction, to decorate the containers or for printing barcodes.

Figure 6: Seen in Court of an edge of lid

Better distribution of material in the area of the skirt with the entry of material from the subsequent stamping grid area, less maintenance costs to repair utensils, reduced downtime due to a rapid change of cutting lines and optimal outcomes of court in the product with a new technique Court in the area of the buttons of grip and durability of the tool due to the limitation of the Court in the mold for molding/stamping.

To process material preprinted, as in the manufacture of closures, a photoelectric cell command device is available. Servomotorizado transport of plastic allowed, along with the photoelectric cell, the exact positioning of the printed plastic in the mold of moulding.

Depending on application and production requirements, the photoelectric cell is located on the machine. The plastic should be brands of printing at the distance of the reasons. The search for the brand of slow printing once adjusted progress to rapid progress takes place. Search cycle ends as soon as recognized brand impression. Plastics will continue to even transporting the distance corresponding to the correction of the mark of impression. This way of working allows regular accurately the position of the printed image.