50-200Tons. Second Generation All-Electric injection molding machine. Victor Taichung - an established ISO-9001 & company

Transcription

1 50-200Tons Second Generation All-Electric injection molding machine Victor Taichung - an established ISO-9001 & 01 company

2 50-200Tons Second Generation All-Electric injection molding machine New Centrally Pressed Platen Clamping Unit Wide platen to satisfy your excellent application requirement. New design of toggle system for improved cycle times, smooth and quiet operation. New Low-friction Linear Guided Injection Unit High speed and fast acceleration functions. High precision injection/holding switching and stable on charging capacity. New Generation VPC0 Control Bigger and higher resolution touch screen. Graphical user interface. Remote monitoring system (Option). Precision Shot Contro High performance servo-mechanism achieves ultimate stable molding. High Productivity Simultaneous operation is inherent to allelectric servo machines, which enables precise high speed molding and more stable conditions. Energy Saving & Environment Energy Saving up to 60% as compared with general hydraulic machine. Quiet Operation! (Low noise) 1

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4 The Robust Clamping Unit The high rigidity clamping unit enables the use of wide platens and achieves ultra reliable molding. Moving platen with the wide span guides on hardened steel ways ensures platen parallelism and to reduces platen tipping with large mold weights. The horizontal distance between tie-bars are extended to accommodate wider, multi- cavity molds as well as larger more complex molds and increases the work space for mold setup. Previous model Extended width between tie-bars V Centrally Pressed Platen structure, improved force distribution The moving platen incorporates a rigid box design cast platen- which is FEM optimized to ensure minimum deflection, maximum control and toggle linkage durability. The centrally pressed platen design reduces platen deflection, this together with increased platen rigidity improves the force distribution and eliminates short shot and flash problems. V -200 (Previous model) New V Moving Platen Surface Pressure Distribution Victor's 5-joint internally folding toggle system enables a faster clamp action The latest 3D simulation software has been utilized to analyze the design and structure of the new toggle system. This has enabled the use of a shorter ballscrew and reduced the mold open / close time. Hard to deflect / Hard to twist Hard to deflect, hard to twist- Tubular steel frame is featured on V machines for maximum rigidity with multidirectional parts removal. 3

5 Quick Response, Low Friction Injection Unit Model V II-50Y (High speed type) V II-50Y (Standard type) Max. injection speed Speed up/ time Decelerating / time Gravitational acceleration 500mm/s 32ms 26ms 1.59G 300mm/s 20ms 26ms 1.53G 50 Tons 300mm/s 48ms 35ms 0.64G Injection Speed (mm/sec) Acceleration characteristics in high-speed injection V II-50( injection speed500mm/s ) V II-50( injection speed300mm/s ) Previous model ( 50 Tons ) Response performance 2-3 fold increase Injection Time (ms) Powerful, high-speed quick response injection unit Precision linear guide bearings are used on the injection unit carriage for smooth and reliable sled movement. Japanese manufactured load cell produces high resolution results, fast injection response and the precise pressure control required for precision molding. The new designed linear guides are optimized for quicker acceleration loads and faster cycles required for thin-wall molding. Driving Torque Injection shaft driving torque loads comparison (Moving speed: 5mm/sec) Previous model VαII-200 A new low-friction linear guide is adopted for supporting and driving the movable platen, enabling friction free movement from extreme low to high velocity. 4

6 New Generation VPC0 Control Intuitive 15 inch touch screen framed by a keyboard The swivel mounted 1 LCD high resolution touch screen, graphical user interface, (A) can be optimally positioned for each operator, allowing an easy setting position and easy access to the mould area. (B) Individual forward and retract manual movement buttons for each axis. (C) The advanced 4KHZ high speed servo control scanning time achieves high precision injection control for high precision molding. Simple Friendly Operation interface Mold settings can be transferred using a USB drive The internal memory allows for up to 0 molds to be stored, the USB port enables molds to be stored to an external USB memory stick. (B) Pop-up keyboards for data and text entry Touch screen panel/pop-up keyboard for user friendly setting and operation. (C) (A) Set point overview screen Single screen for setting clamp, ejector, injection, temperature, air-blast and charging etc. Great for quick setups and adjustments. Improves operator setup efficiency. Remote monitoring system PIS (Option) Individual computer Ethernet Production management - quality control Records various quality control and production metrics and has the facility to set machine stop conditions. HUB HUB 5

7 Excellent Injection Performance High precision shot control and stable charging capacity The Injection and charge operations have a linear control profile this enables a stable high precision shot. High precision and high resolution back pressure control in 1kgf/cm² unit (during metering) Previous model V Actual min. injection position (mm) Holding switching position Injection/holding switching position input value (mm) High performance holding decompression control The new controller improves decompression control speed while injection/ holding switching, this reduces defective products. Stability weight of products Products weight (g) Products details (PC) MAX g MIN g AVE g R(g) 0.024g 1CV 0.03% Times Jerking restraint WV 0.19% Improved mold open/close control The new generation control system allows an improved ramp up /down control and a quicker response time this enables a smoother mold operation. Utilizes the S-Curve acceleration/deceleration algorithm to smooth out the abrupt starts and stops, not just the jerk minimized but also prolongs the service life of mechanical parts. Mold open/close speed Mold open/close Jerking frequency Mold closed Previous control system (Tradition Trapezoidal profile) New VCPC0 control (S-Curve profile) Mold open S-Curve Trapezoid-Curve 6

8 High Productivity Simultaneous operation is inherent to all-electric servo machines, which enables precise high speed molding in more stable condition. The electric servo-drive axis work independently with high precision, high dynamics and low noise emissions. Each of the operating axes has its won independent drive and can therefore utilize all the advantages associated with such a design. This enables simultaneous operation of all functions and reduction of dwell times to an absolute minimum. Ex. All-electric VS. Hydraulic cycle time reduction comparison Vs- Hydraulic (With ACC) Clamp Close Lock- up Cycle Time 5.1 sec Filling / Packing Cooling / Metering Clamp Open Eject V - HS All- Electric Clamp Close Cycle Time 3.1 sec Lock- up Cooling / Metering Filling / Packing Mold pre-break up Clamp Open Saved2.0 sec Eject Test data Comparison of cycle time savings Product Pudding cup Weight 6.9g / each Resin PP %Shorter 0 Cycle Time Hydraulic All-Electric 7

9 Energy Saving From V All-Electric Huge energy saving cuts molding costs, plant construction and operation costs. All-electric machines dramatically reduce operating costs, using 50 ~ 80 percent less power than equivalent hydraulic machines. Connected power requirements for an electric machine are 30% those of a hydraulic machine. Furthermore factory equipment cost is saved (such as air conditioning, cooling water etc.) and also low noise levels improve plant environment. Cooling water usage saving to 1/5 or less of the hydraulic machine. No hydraulic oil. Thanks to a smart regenerative power module, the braking energy recovery during clamp deceleration and other functions. This power is stored and re-used. Clamp Close Filling Packing Metering Cooling Clamp Open Eject Hydraulic machine (Vs-50T) Power consumption Electric machine (V -50T) Time Power consumption Cooling water consumption (KW/hr) (Liter/hr) Cycle Time Hydraulic machine Electric machine Cycle Time Hydraulic machine Electric machine Quiet, Clean operation environment An independent 3-path centralized greasing system manages the proper lubrication amounts and intervals to the ballscrew and toggle-pin sections. Noise value (Tested model: 200T) Hydraulic machine All-electric machine Difference Injection side 81dB 69dB 12dB Clamping side 79dB 74dB 5dB Centralized lubrication system Easy clean, pull out grease tray 8

10 General Design Features Control unit Advanced Victor PC0 controller - Pentium PC based on industrial standard 1 TFT colour LCD operating panel 48 x DC24 Volts output points 48 x DC0.5 Volts input points 20 Mhz ADSP 1 servo processor Multi-language selection (Chinese, English, Japanese, Portuguese, Polish) Other language selection Independent operation capability of each axis (clamp, eject, injection and charging) Clamp / Ejection Clamp close 5 steps/ Clamp open 5 steps digital control Advanced mold protection control One stage injection compression software Multistage injection compression software Mold-set mode follows an safety moving speed on clamp/ ejector for mounting the mould Auto die-height/ clamping tonnage adjustment Clamping force monitoring 2 Stages ejector (Advance x 2/ Retreat x 1 speed digital control) Eject on the fly Ejection delay timer In- mold degating/ Pre-ejector software Advance ejection protection control Digital clamp/ ejection position display +/- 0.1 mm repeatability of clamp/ ejection functions +/ mm repeatability of clamp/ ejection functions Robot arm coming in during mold opening function Temperature Control Auto synchronized nozzle/ barrel heat-up control Nozzle/ barrel temperature digital setting Thermocouple breakage detection PID auto tuning of temperature control 7 spare sections for optional temperature circuit 7-days timer for auto heating and preheating Shut down sequence- lower temperature by idle timer or alarm All zones temperature heating- waveform tracing Separate / unit selection capability Feed throat temperature display Heater failure detection-hardware/ Software Print / Storage 0 mold file capacity Alphabet name file capability Last storing log Molding parameters print out (Note 1) Selectable process data print (Note 1) Note 1) The soft copy via the USB ports. 9 Injection / Plastication Load-cell close loop control for the complete injection profile/ metering pressure Pre-injection function Independent operation of recovery during clamp operation Selectable surge-pressure cut transfer mode Injection 6 steps/ Pack 4 steps digital control Screw rotation/ pressure 4 steps control V-P transfer based on time, position and pressure Digital indication of screw pressure, speed, position and decompression Cavity pressure dependent changeover from filling to holding pressure Signal dependent changeover from filling to holding pressure Two stage automatic purge sequence Injection start delay timer Cold screw start prevention Charging start delay timer Suck-back function Pre-suck back function. Decompression prior to charge Sprue break function (Changeable injection unit retreat timing) +/-0.01 mm shot size accuracy Advanced melt pressure control Production Management Production management setup Alarm history (Up to 0 items) Alarm message logging/ diagnosis display Consecutive bad-parts alarm Cavity No./ cycle counters Power on time/ Run hour display Container production management Servo fault alarm Charging time alarm Temperature alarm Thermocouple breakage alarm Heater failure alarm Grease lubrication fault/ used up alarm Resetting cycle counter Monitor Molding condition upper/ lower limit monitor Injection profile waveform monitor Charging back-pressure waveform monitor 0 cycles statistical processing of monitored date (SPC) Graphic display cycle step & time monitor Process parameters plotting monitor I/O diagnosis monitoring screen Servo processing condition monitor

11 Standard/Option Equipments Injection Unit Clamping Unit Pivoting injection unit Injection unit guided on linear guide way Spring shut-off nozzle Pneumatic actuated needle shut-off nozzle Hydraulic actuated needle shut-off nozzle( 1) Slides shut-off hopper for quick material change Thermoset package Thermocouple controlled nozzle zone SSR control for heaters Rigid PVC package Increased nozzle touch force ( 2) High pressure/ speed injection unit ( 3) Stainless steel barrel cover Nozzle purge shield General-purpose nitrided screw and barrel Corrosion/ abrasion resistant screw and barrel (Bimetallic coating) ( 7) Chromium-plated screw Multi-notch locking style screw tip Plug-in ceramic band heaters Feed throat temperature control Auto loader Long nozzle as accessory Band heaters up to 450 ( 4) Braided band heaters Hopper + magnet Communication / Interface RS232 Data interface for printer/ Process information monitoring system (PIS) ( 6) Ethernet communication TCP/IP capability via auxiliary Victor standard interface for robot-terminals in cabinet Euromap12/ 67 for robot interface Mould heater control hardware Masterbatch colour dosing device interface Core pulling device interface Unscrewing motor interface Valve gate interface Ejector plate retract confirmation interface Container signal output-terminals in cabinet General Alarm lamp 3 Color warming tower Alarm buzzer Core pull and ejection motion/ no motion mode seletion while gate is open in semiauto mode Ground fault breaker Designated machine guarding color 10 Mechanical safety/ ratchet bar Electric & ring gear driven die-height adjustment Selectable locating ring diameter to fit the mould Adjustable moving platen supports on hardened steel plates Movable platen with wide-span & skatetype supports Stainless steel drop chute Centralized automatic grease lubrication for ball screws on clamp/ injection unit Chromium plated tie bars Hardened steel chromed toggle pins and phosphor bronze oil-less bushings Manual lubrication for die-height adjusting mechanism Centralized automatic grease lubrication for toggle Platen holes fit to JIS, Euromap or SPI specification Additional mould height Clamp unit safety gate operator and rear side Clamp unit top cover for safety Mould top cover for safety and mould protection Part drop area covers for safety Robot fixing platen on top of stationary platen (Euromap-18) High speed ejection (Eject force is limited) Increased ejection force (See technical data) One stage air blast (Moving platen side) 3-Way valves for air blast/ air shut-off nozzle Second/ third stage independent air blast ( 5) Servo-electric/ Electric/ hydraulic driven unscrewing motor ( 1) Pneumatic/ hydraulic actuated core system ( 1) Tri-directional part removal base design Full-access connection to center ejector T-slotted die platens ( ) Servos / Controls High resolution absolute pulse encoders No liquid cooling. No water required. Air cooled high-power/ low inertia Sanyo Denki AC servo motors High energy efficient Sanyo Denki servo amplifiers Separate Metric/ English unit selection capability VPC0 control features include PS2 keyboard port, USB port, Ethernet port, USB port and parallel port ( )V Ⅱ-300 Standard

12 Accessory Tool/ fuse kit Part drop chute Conveyor belt Standard 5-in's/ 5-out's water regulator without flow indicator 4 or extra zones water regulator with the flow indicator Anti-vibration leveling pads 220V/ 380VAC outlet x 1 for auto loader 110VAC outlet receptacle (power sourced by customer) 110VAC outlet receptacle (power sourced via machine) AC 220V/ 380VAC outlet receptacle (power sourced by customer) AC 220V/ 380VAC outlet receptacle (power sourced via machine) Transformer for local power source Notes: ( 1) For the hydraulic type, a separate hydraulic unit is needed ( 2) Increased to 2.0 ton from standard 1.5 ton/ Increased to 3.0 ton from standard 2.0 ton/ Increased to 4.0 ton from standard 2.5 ton ( 3) The high speed differs depending on injection unit ( 4) Standard band heater can be used at a maximum working temperatures of 360 / High watts band heaters are available as optional as for the use in high working temperatures up to 450 ( 5) 3 stage independent air blast (One for stationary platen side/ two for moving platen side) ( 6) PIS monitoring system via an optional auxiliary ( 7) Depending on the kind of quality steel used and the abrasive/ corrosive engineering resin & additives for application, there are A, B and C three grades of bimetallic barrels on choosing, see the descriptions on the right A Grade bimetallic barrel and screw set- with 40% tungsten carbide composition included in the barrel's bimetallic content, coupled with a screw which entire surface is fully hardened through HP/HVOF coating treatment process. B Grade bimetallic barrel and screw set- with 25% tungsten carbide composition included in the barrel's bimetallic content, coupled with a screw which entire surface is fully hardened through HP/HVOF coating treatment process. Sectional drawing of screw spindle with HP/HVOF treatment (A & B Grade Screw Spindle) Entire screw surface being fully hardened by spray coating process Screw body C Grade bimetallic barrel and screw set- with 9.5% tungsten carbide composition included in the barrel's bimetallic content, coupled with a screw which only the flights-tip is hardened through PTA Bimetallic alloy treatment process. Sectional drawing of screw spindle with PTA treatment (C Grade Screw Spindle) Only screw fights tip being hardened by PTA treatment process Screw body For the bimetallic barrel selection details contact Victor sales Example of standard/ optional equipment AC 220V/ 380VAC outlet receptacle 110VAC outlet receptacle The separate hydraulic unit for actuating core pulling or unscrewing device Hydraulic unscrewing motor Core pulling device interface & Ejector plate retract confirmation interface Centralized automatic grease lubrication device for ball screws & toggle-pins Part drop chute The appearance and the specification of machine may be altered for betterment without notice 11

13 EUROMAP platen information V II-50 Moving platen M12 4-ø30 ø ø Ø 60 25or M12 ø or ø V II-80 Moving platen M12 4-ø30 ø ø Ø or M12 ø or ø V II- Moving platen M16 4-ø30 ø ø Ø or M16 ø or ø V II-150 Moving platen M ø30 ø160 ø Ø 30or M16 ø or ø V II-200 Moving platen M ø30 ø160 ø Ø or M20 ø or ø

14 SPI platen information V II-50 Moving platen 16.~24.4" 10.6" 5.9"~13.8" 12.2" 4-Ø1.2" 28-5/8"-11UNC Ø2.8" " 19.8" Ø2.8" 2.4" 1" or 2.6" 28-5/8"-11UNC Ø4" 12.2" " " 19. V II-80 Moving platen ~27.6" 12.6" 5.9"~1 13.4" 8. 4-Ø1.2" /8"-11UNC Ø " 20.9" Ø3. 3.1" 1.2" or 2.6" /8"-11UNC Ø4" 14.2" 22.6" " 22.8" 16.1" 22.8" V II- Moving platen 20.1"~31.9" 14.2" 5.9"~ " 44-5/8"-11UNC 4-Ø1.2" Ø " 22.8" Ø3. 3.1" 1.2" or 2.6" 44-5/8"-11UNC Ø4" 16.1" 24.2" " 24.8" 18.1" 25.2" V II-150 Moving platen 1 21.~34.6" "~18.9" 14.2" /8"-11UNC 8-Ø1.2" Ø4.9" 2" 2" " 28. Ø4.9" 3.9" 1.2" or 2.6" 48-5/8"-11UNC Ø4" 20.1" " 8" 22" " 31. V II-200 Moving platen "~40.2" "~ /4"-10UNC 8-Ø1.2" Ø4.9" 2" 2" " 31. Ø4.9" 5.9" 1.2" or 2.6" /4"-10UNC Ø4" 22" 32.9" " 8" 24" " 34.6" 13

15 JIS platen information V II-50 Moving platen M16 4-Ø30 Ø Ø 60 25or65 32-M16 Ø V II-80 Moving platen M16 4-Ø30 Ø Ø or M16 Ø V II- Moving platen M16 4-Ø Ø Ø or M16 Ø V II-150 Moving platen M16 8-Ø Ø Ø 30or M16 Ø V II-200 Moving platen M16 8-Ø30 Ø Ø or M16 Ø

16 D C J I Euromap Specifications Model V II-50Y V II-50X V II-50K V II-80K V II-80H Injection Unit Screw Dia. mm Theoretical Displacement cm Inj. Capacity Max. (PS) g oz Max. Inj. Press kgf/cm Max. Pack Press. kgf/cm Plasticizing Capacity PS kg/hr Screw L/D Ratio Standard type High speed type (Option) Inj. Rate cm 3 /sec Inj. Speed mm/sec Inj. Rate cm 3 /sec Inj. Speed mm/sec Screw Stroke mm Screw Speed rpm 0~3 0~3 0~3 0~3 0~3 Nozzle Touch Force ton Clamping Unit Clamping Force ton Max. Clamp Stroke mm Min./Max. Mould Height mm Max. Open Daylight mm Tie-bar Distance (H x V) mm 360 x x 360 Platen Dimensions (H x V) mm 500 x x 530 Ejector Stroke mm Max. Ejector Force ton / 3.3 General Specifications Machine Power Supply Capacity (Standard/High Speed) kw 7.83 / / / / / Machine Transformer Size (Standard/High Speed) KVA 17 / / / / / 43 Machine Weight ton Machine Dimensions (L x W x H) mm 3589 x 1243 x x 1329 x 1971 Input Power Source 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz Notes: Due to continual improvements, specifications technical imformation and dimensions are subject to change without prior notice. Machine Layout H E F G A B 15

17 V II-K V II-M V II-150M V II-150G V II-200G V II-200F ~3 0~3 0~3 0~3 0~3 0~ x x x x x x / / / / / / / / / / / / / / / x 1388 x x 1601 x x 1582 x VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz Model A B C D E F G H I J Net weight (ton) VαII VαII VαII VαII VαII-200 G VαII-200 F

18 SPI Specifications Model V II-50Y V II-50X V II-50K V II-80K V II-80H Injection Unit Screw Dia. in Theoretical Displacement in Inj. Capacity Max. (PS) g oz Max. Inj. Press Psi Max. Holding Press. Psi Plasticizing Capacity PS g / s Screw L/D Ratio Standard type High speed type (Option) Inj. Rate in 3 /s Inj. Speed in/sec Inj. Rate in 3 /s Inj. Speed in/sec Screw Stroke in Screw Speed rpm 0~3 0~3 0~3 0~3 0~3 Nozzle Touch Force U.S. ton Clamping Unit Clamping Force U.S. ton Max. Clamp Stroke in Min./Max. Mould Height in Max. Open Daylight in Tie-bar Distance (H V) in Platen Dimensions (H V) in (Moving) / (Fixed) (Moving) / (Fixed) Ejector Stroke in Max. Ejector Force U.S. ton / 3.63 General Specifications Machine Power Supply Capacity (Standard/High Speed) kw 7.83 / / / / / Machine Transformer Size (Standard/High Speed) KVA 17 / / / / / 43 Machine Weight U.S. ton Machine Dimensions (L W H) in Input Power Source 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz Due to continual improvements, specifications technical information and dimensions are subject to change without prior notice. 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz a Servo driver cabinet open space i h g e d f c b Electrical cabinet open space Recommendation of operate space 17

19 V II-K V II-M V II-150M V II-150G V II-200G V II-200F ~3 0~3 0~3 0~3 0~3 0~ (Moving) / (Fixed) (Moving) / (Fixed) (Moving) / (Fixed) / / / / / / / / / / / / / / / VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz 220 VAC 10% 3Ph 60 1 Hz or 200 VAC 10% 3Ph 50/60 Hz 1 Hz Model a b c d e f g h i VαII VαII VαII VαII VαII

20 UK GERMANY FRANCE CHINA USA THAILAND TAIWAN MALAYSIA SOUTH AFRICA Worldwide Subsidiaries R Orders Repeated To ensure the return on investment, Victor Taichung has invested considerably in setting up a distribution network in terms of global vision local touch for our sales and service supports worldwide. Besides the qualified exclusive agents around the world, Victor Taichung has 9 overseas subsidiaries to provide our customers efficient after-sales service and technical supports. Victor Europe (UK) Victor France Victor GmbH (Germany) Jianrong (Victor Shanghai) ProCoMeS (Italy) Perytone (Russia) Fortune International (USA) Victor Fortune (South Africa) Victor Malaysia Swiss Machinery Import Gibas Numeriek (Benelux) HiMAQ (Argentina) THE VICTOR-TAICHUNG COMPANIES HTL VTL VMC HMC XMT PIM TEL: TAIWAN info@mail.or.com.tw Victor Taichung Machinery Works Co., Ltd. Headquarters: 2088, Sec. 4, Taiwan Blvd., Taichung, Taiwan, R.O.C. TEL : FAX : Overseas Marketing Division: TEL : FAX : UK Victor CNC (UK) Ltd. TEL : FAX : FRANCE Victor France TEL : FAX : GERMANY Victor GmbH TEL : FAX : MALAYSIA Victor Machinery (M) SDN. BHD. TEL : FAX : THAILAND Victor (Thailand) Co. Ltd. TEL : FAX : INDONESIA PT. Victor Machinery Indonesia TEL : FAX : USA Fortune International Inc. TEL : FAX : SOUTH AFRICA Victor Fortune (PTY) Ltd. TEL : FAX : CHINA Zhongtai Precision Machinery (Guangzhou) TEL : FAX : Va GC15EC