DP400 High Speed Preform Injection System Technical Specification
A. Brief Introduction for DP400 - Innovation and Improvement
Brand new servo hydraulic system design
l The whole hydraulic system is driven by servo motor.
l Reduce cycle time with synchronized design: melting PET at the same time while other movements are proceeding.
l 4 sets of nitrogen tank with high pressure filter.
l Injection, mold movement and ejecting are all controlled by Rexroth servo cylinder.
l Equipped with separated filtering and cooling system for oil whose accuracy could reach 20um.
l The advantage of servo control:
a. Low power consumption: When the machine is cooling or without any movement, the servo speed is less than 10 RPM which the energy consumption is almost 0. While normal electrical motor speed around 1500RPM. The output point of servo hydraulic oil directly connected with the directional valve who control the movement to save energy. While normal machine has to though flow control valve.
b. Precision: Pressure sensor make the accuracy of servo hydraulic system reach 0.1bar.
c. Fast react: It only takes 0.12s for the pressure and speed to reach maximum output.
Control system
The project is leading by Mr. He -former HUSKY engineer who was in charging of the developing injection machine control system. Applied with his new generation PC based BECKOFF injection system control solution, Demark machine could has following advantage:
l Stable and fast cycle time.
l Fast PCL execution time.
l High performance PC and fast I/O capability.
l Quick communication thought all control components.
l Self-adjustment and self-adaption.
l High level control algorithm for speed, pressure and temperature. High level control strategy for reducing energy consumption.
l Friendly user interface design.
l Intuitive icon design for fast learning and control.
l Fast information reading by press less buttons.
l Single function button design.
l Clear and accuracy alarm function.
l Detailed event log.
l 15 Inch touch screen, 2.1G dual core CPU, 3GB memory and 80GB hard drive equipped.
l No touched electronic ruler with longer life time, and EtherCAT digital single with stronger anti-interference capability.
Temperature control system
l Equipped heater from Italy and protector outside the heater.
l The accuracy of temperature could reach ±1 degree with PID control.
l The constant power module makes the mold temperature stable and non-influenced by the voltage.
Cooling Robot
l Sliding and flipping unite are designed as a whole which could have more stability.
l Easy adjustment for the distance between robot plate and mold.
l Three station cooling plate.
l LENZE servo motor and Alpha reducer make the movement accuracy and quiet.
l Siemens vacuum pump.
Plasticization & Injection
l Barrier design screw improved the plasticization effect.
l Screw with chrome and the L:D ratio reach 25:1.
l By equipping material storage unite, the machine could melting and injection at the same time.
l Using servo motor from Germany for melting.
l Back pressure could adjust on the control panel.
Clamping Unit
l Special clamping parameter design for PET make the mold open & close stable and fast.
l Strong mold plate make the mold get pressure balanced.
l Square design which matching the mold.
l Also compatible with HUSKY mold.
Ejection Unit
l With more ejecting pin make better ejection.
l Bigger ejecting force than normal machine.
l Ejecting stop work with the light sensor which protect the mold.
Innovation on water and gas circuit
l Centralized cooling water supply for mold, robot and auxiliary machine.
l Stainless quick plug for cooling water.
l Needle control in the mold use the MAC big volume valve which improve the speed and stability.
l Using SMC valve for high pressure air and vacuum transmitting.
High reliability of the whole machine
l The clamping unit is welded by H type steel.
l Injection unit using 10mm steel while robot frame using 120mm square tube.
l Equipped several parts of PC board which let the operator see machine inside clearer.
l Beautiful out looking and color design.
B. Technical Parameter for DP400
| ITEM | DP400 |
INJECTION
UNIT | Screw L/D Ratio | L/D | 25 |
| Screw Diameter | mm | 120 |
| Injection Pressure | kgf/cm2 | 1000 |
| Theory Shot Volume(Max) | cm3 | 4100 |
| Shot Weight(PS) | g | 5000 |
| oz | 175 |
CLAMPING
UNIT | Clamping Force | T | 300 |
| Clamping Stroke | mm | 585 |
| Max/Min Thickness of Mould | mm | 300~720 |
| Space Between Tie Bars (WxH) | mm | 660x760 |
| Ejector Stroke | mm | 180 |
| Ejector Force | T | 20 |
| NO.of Ejector Pins | pcs | 5 |
| Max Pressure of System | kg/cm2 | 180 |
| MOULD | Cavity(Max) | PCS | 72 |
| Neck of Bottle(Max) | mm | 42 |
| Length of Preform(Max) | mm | 190 |
| Weight of Preform(Max) | g | 35 |
| Type of Mould | Needle Valve of No-Cutting PET Preform Mold |
|
POWER
UNIT | Motor Power | KW | 75+110 |
| Robot Power | KW | 15 |
| Melting Heater Capacity | KW | 100 |
| Mold Heater Capacity | KW | 55 |
| ROBOT | Manipulator | cavity | 216 |
| Cooling Form | cavity | 216 |
| Size (LxWxH) | cm | 263X157X230 |
| OTHER | Electric Power Supply
(3-phase AC) | V | 380 |
| KW | 335 |
| Chilling Water | ºC | 5~12 |
| Mpa | 0.8 |
| L/min | 900 |
| Cooling Water | ºC | <25 |
| Mpa | 0.3 |
| L/min | 300 |
| Compressed Air | Mpa | 0.7~0.9 |
| L/min | 800 |
| SIZE | Machine Size (LxWxH) | cm | 990X180X250 |
| WEIGHT | Machine Weight | T | 28 |
C. DP400 Brand Specification
| Name | Brand | Country |
| Mechanical and hydraulic system |
| Oil pump | VOITH() | GERMANY() |
| Charging servo motor | PHASE() | CHINA() |
| Servo melting motor | KNODLER | GERMANY() |
| Accumulator | HYDAC() | GERMANY() |
| Servo valve | REXROTH() | GERMANY() |
| Directional valve | REXROTH() | GERMANY() |
| Oil sealing | NOK | JAPANESE() |
| SEALTECH() | EUROPE() |
| Filter | HYDAC() | GERMANY() |
| Pressure gage | HP() | CHINA() |
| Pressure sensor | HYDAC() | GERMANY() |
| Oil cooler | KAMUI() | CHINA() |
| Pipe connector | EATON() | USA() |
| /Screw & barrel | HUAYE() | CHINA() |
| Tie bar | JENERAL() | TAIWAN() |
| Heater | Z.R.E | ITALY() |
| Linear guilder | THK | JAPANESE() |
| Bearing | NSK | JAPANESE() |
| (Pneumatic system) |
| (Air valve) | MAC | USA() |
| SMC | JAPANESE() |
| FESTO | GERMANY() |
| (Low pressure regulator) | SMC | JAPANESE() |
| (Air cylinder) | AIRTAC | TAIWAN() |
| (Vacuum) | SIEMENS | GERMANY() |
| (HOT RUNNER SYSTEM) |
| (Heater coil) | HOTSET | GERMANY() |
| (Temperature controller) | SIEMENS | GERMANY() |
| (Manifold heater) | ZOPPAS | ITALY() |
| (Valve stem) | PUNCH | JAPANESE() |
| (ELECTEIC CIRCUIT |
| Computer control system | BECKHOFF() | GERMANY() |
| (Robot Servo motor) | LENZE() | GERMANY() |
| (Magnetic relay) | ABB | Swiss() |
| (Photo electric sensor) | OPTEX | JAPANESE() |
| Main switch | ABB | Swiss() |
| (Proximate switch) | TE | FRANCE() |
| SICK | GERMANY() |
D. Auxiliary machine
Dehumidifying dryer
With two space of drying and dehumidifying, the machine is suitable for drying the raw material with the following specification:
l Power 400V 50HZ 3P+PE.
l 24VDC and 230VAC subsidiary loop. Machine design meet CE standard.
l System electronic board control with LCD screen man-machine interface.
l High precision PID heating control.
l Two drying hopper with stainless steel heat desiccant beds.
l High pressure fan for desiccant beds.
l HT version exchange switch for two desiccant beds.
l Air return and regeneration heat exchanger.
l Solid state relays for process heater control.
l Regeneration heater.
l Self-protection unit for the heater avoid overheating.
l Dew point less than -40°C.
l Dry air temperature 60-190C.
l Pressure difference sensor for the return air filter to avoid blocking.
l Acoustic and Visual Alarm.
l Stainless pipes.
Stainless drying hopper
l Add-on heater.
l ANSI 304 stainless steel construction.
l 100mm insulation layer.
l High temperature resistance air output filter.
l Observation door with 100mm insulation layer.
l Directly install material collector on the top.
l Manually control pneumatic material dropping valve.
l Continuous material level gage.
Vacuum pump
l Motor (400V/3P/50HZ)
l CF2 type filter with 6.75M2 cleaning area and 8um filter precision
l Automatic filter cleaning
l Filter clogging pressure switch
l Maximum noise level <75dB(A)
Vacuum auto loader
l ANSI 304 stainless steel construction
l Stainless steel internal grid filter and steel sealing
l 50mm dia vacuum breaker valve
l HT version magnetic level sensor
l Ø50 mm material connections
l Closed type testing port
Pipes
l 50mm stainless loading pipe
l 50mm PU pipe
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