Broad production programme

A Danish processor has turned the advantages of the termomoldeo in a broad and versatile production program. The expansion of its fleet of machines thanks to a new machine of termomoldeo of Illig, represented by Helmut Roegele, opens up the possibility of new dimensions in the castings.

Gibo-plast, Skjern (Denmark), manufactures complicated castings of different colours and structures using modern methods of manufacture. Individual ideas and short paths between the construction and manufacturing allow short realization times. They use different technologies of operations and processes assisted by vacuum or air compressed, as well as the procedure twin-sheet. The termomoldeo have 16 machines au (manufacturer: Adolf Illig Maschinenbau, Heilbronn) of various sizes and versions. With the acquisition of the new machine UA 300 g emerge new dimensions in terms of molding surface and depth of drawing.

The wide equipment of the machines allows you to use always the optimal and most economical to manufacture machine. During the development and optimization of products and processes it allows to choose the most efficient technique.

Gibo-Plast has the advantages of the termomoldeado become a broad program of production with corresponding know-how. Thus, company manufactures cabins for driver of agricultural machinery (cover photo), pieces of covers, various types of roofs and elements carriers in considerable quantities. Exploit fully the possibilities of the termomoldeo in various products: grooves of reinforcement, insurance against torsion, inclined planes, and holes for the output of fluids, structures of surface, logos and signs molded, dyed semiproducto, etc.

Thanks to the accurate execution of work pieces also pieces that fit perfectly together, which are then assembled to form a complete unit can be manufactured. In case of negative pieces or pieces with structures and carvings, the compressed air moulding is the appropriate procedure. In order to produce economic mode, almost all machines are equipped with automatic load of plates. Six of used machines are also available, for processing materials in coil.

Bulky parts are manufactured by molding by vacuum. In the UA 300 machine g can produce parts up to 2000 x 3000 mm, being possible depths of drawing up to 1000 mm. Various procedures further, such as CNC machining or stamping, gluing and welding of plastic parts are used to manufacture castings of high accuracy with multiple forms and functions.

To ensure that the quality of production remains just as high, it is important to equip the new machine of termomoldeo with a basic setting assisted by computer. For example, after you enter the basic data of the technique of processes through the system of command of the machine, adjustment data adapted to the practice, for all the functions of the machine can be calculated. These data can be optimized while production underway and can be stored in the system of command. If a product is made repeatedly is not necessary to perform each time the work of adjustment, but data are immediately available; the termomoldeo process is reproducible, and excluded all failure of adjustment. The previous blown functions, prior aspiration, empty prior, vacuum moulding, desmoldeo and heating times are scheduled according to the procedure teach-in. If the operator interferes with these functions through the keys soft-key, the system of command of the machine will take time as the theoretical value for the next cycle and will store this data in the program's sequence. For each application there is the optimum setting.

The newly-developed command of machines, for industrial PC (Siemens Panel PC/WIN 2000), allows to intervene in the process of termomoldeo of even simplest way, while such interventions tailored specifically to the termomoldeador. The onscreen Guide for the operator, with its menu pages, allow permanent access to all data related to the process and allows, in the event of faults, immediately locate the origin of these bugs in the installation and the process.

For example, to generate the forces of closure for the moulding twin-sheet molding table and the above table, this machine were used to hydraulic drives. Prior aspiration, the previous blown, the vacuum and the anti-corrosion can be adjusted with precision without steps and reproducible way. So you can pretensar and shape with more precision the areas with large stretched. This in turn has as a consequence the use of thinner semi-finished products and contributes to greater profitability.

For processing plates of different thicknesses it is not necessary to make additional adjustments, up to 10 mm has place an automatic compensation. This also occurs in the UA 300 g with automatic plate loading.

If the semiproducto is too hot, avoid the camber of the plate applies to compressed air, which is under control of the plastic rope. For the main sequences of movements there are measuring systems of routes for the regulation of the position.

The condition for a result of high-quality moulding is a careful and uniform heating of the semiproducto. The optimal parameters of manufacturing are obtained thanks to the heating of regulated temperature. These are based on the philosophy of the manufacturer of the machines: regulate instead of putting. The heating are equipped with high-temperature ceramic resistors. The area of radiation is completely closed for so effective performance; This guarantees a general warming across the surface of the semiproducto for any size of tensor framework, including the area of the edge.

Easy handling and the effectiveness of smaller au machines became requirements for large format machines. Why UA 300 g is equipped with a device of automatic plate loading. Given that the cycle time is determined, among other things, the time of heating and cooling, the solution is to optimally harness existing heating techniques. Why Gibo-Plast decided to equip cargo with top and bottom heating station, in order to use the technique of previous heating or end processes. The technique of applied heating is based on the moulding machine. The process of warming can occur in parallel to the process of moulding and cooling, which will involve considerable short and, consequently, cycle time increases in productivity.

The machine is loaded directly with semi-finished products from the pallet. It is inserted into the machine using a Stacker truck. To always find the correct position should align the stack of plates to a mechanical ceiling (wall of stacking) on the device of load. It has a longitudinal and transverse caps with respect to the direction of movement, and their positions are put in place automatically and can be stored in memory.

The eleva-placas powered by servo motor allows optimized translation movements. For example, by raising the plate are possible a movement slow to separate plates and a rapid translational motion until you reach the level of separation. A nozzle of air separation Additionally blows air below the plaque. A sensor measures the default thickness of the plate during transport and recognizes when two plaques are elevated. Plates are deposited in a mobile centradora Panel, for its proper accommodation, and the eleva-placas back them to stay, during which no extends the range of work or scratches the delicate surface of the plates. You can compensate for a redshift of ± 50 mm.

In this machine, vacuum cleaner plate is replaced by the newly developed vacuum unit. It is adjustable and can adapt to the various formats. In addition, this unit has an angular elevation which moves separately, that makes the process of separation even safer.

In the machine also joined the rapid change of mould, easy to use, with the automatic program of re-equipment. For the first time, it is possible with these dimensions to introduce on the machine the package of complete moulding (mold for molding, upper and lower tensor framework, incl. upper piston). A few levels of roller in front of the opening of the machine providing the introduction of the moulding of single-mode package, as is the case in small machines. The mold for molding focuses on its own and is tense at the table by vacuum molding. Once closed the front door, the functions occur automatically through the re-equipment program. The memorization of data to facilitate the subsequent boot has a positive effect on the time of preparation. This is especially beneficial for small amounts that require frequent changes of format.

The unloading of parts moulded on a table of download that moves vertically takes place according to the process of moulding and transport. To avoid that they dumped the castings, the transfer thereof is first performed at the angle of incidence on the transport of plates; thus avoiding damage to abandon the transport of plates, as for example, the rupture of the embedded piece. After depositing them, the table back to its horizontal position and then at the height of the taking of parts. For an ergonomic desk of the molded parts, the table back into tilted, so position the embedded piece can retire in the sense of movement.