IMC-60B Automatic Aluminum Tube Filling & Sealing Machine OPERATION MANUAL

Transcription

1 INTERNATIONAL MACHIINE CONCEPTS IMC-60B Automatic Aluminum Tube Filling & Sealing Machine OPERATION MANUAL

2 1. Use Instructions CONTENT 1. Summary 2. Working Principle 3. Technical Parameters 4. Structural Features 5. Equipment Transportation and Installation 6. Safety Notes 7. Operation Procedures 8. Operations of Touch Screen 9. Basic Adjustments 10. Adjustment of Automatic Tube Feeding System 11. Adjustment of Transmission Part 12. Disassembly and Cleaning 13. Daily Maintenance 14. Common Malfunctions and Troubleshooting 2. Packing List 3. Certification 4. Electric Circuit Diagram (Attachments) Page 1 of 39

3 1. Summary produced by our company has such features as smooth and flat surface, free of dead corner, being innoxiously and non-smell, free of pollution, easy cleaning, and easy maintenance and servicing. Thanks to the compact structure, simple and convenient operation, the machine is applicable to the demands of users from the industries such as medicine, food and daily chemical industry etc. The machine can smoothly and accurately fill various paste, ointment and viscous fluids etc. materials into the aluminum tube through the filling system. The operations such as filling, sealing and batch No. printing (date of manufacturing) etc. for aluminum tubes can be realized through the folding mechanical hands. The highest production capacity of the machine can reach 3000 pieces/hour with an error of filling volume not more than ±1%. 2. Working Principle Put in order the aluminum tubes to be filled on the tube bucket. Through the Thank you for your using the automatic aluminum tube filling & sealing machine produced by our company. With the design, manufacturing, assembly, debugging, as well as main parts and materials being fully in accordance with GMP requirements, the automatic aluminum tube filling & sealing machine automatic tube feeding device, they will be automatically inserted into the cup seats (positioning molds). The cup seats will rotate with the rotary table so that they will be positioned at different work stations. Put the ointments for filling into the lockable cone hopper. Through the plunger type quantitative filling valve directly connecting with the hopper, they will be accurately and automatically filled into the aluminum tubes staying at intervals on the work stations of filling. The rotary table will continue its rotation and rapidly bring the aluminum tubes that have been filled with ointments to different work stations of sealing. The mechanical hand at each Page 2 of 39

4 work position will instantly seal the tube tail. Different filling volumes can be achieved through adjusting the filling volume adjusting dial. The sealing operation of aluminum tubes with different folding forms such as two-side folding, three-side folding and saddle-shape folding can be finished through changing different mechanical hands. After the sealing is finished, the mechanical hand for code printing will automatically print the words such as date of manufacturing and production batch No. onto the tube tail. Through the automatic tube discharging structure, the finished tube will be automatically sent into the tube collecting vessel. 3. Technical Parameters Filling range: Filling accuracy: Production speed: Aluminum tube diameter: Aluminum tube length: Hopper volume: Power supply: Air pressure: Machine power: Motor power: Outline dimensions: Machine weight: 5-150ml/tube (adjustable) ±1% tubes/hour Φ10-32mm 185mm (max. length) 40 L 380V/220V (optional) MPa 2 kw 1.1kw 1900(L) 850(W) 1900(H)mm about 850kg 4. Structural Features 1. Reasonable structure design The machine has fully embodied the design conception of advancement, reliability, reasonability of pharmaceutical equipment required by GMP, and artificial factors have been reduced during the use. Linkage design is adopted for Page 3 of 39

5 the automatic feeding of tubes, the automatic positioning of tube color codes, filling, sealing, batch No. printing and discharging of finished products so that all the actions are synchronously completed. 2. The requirements of materials to filling technology have been fully satisfied. a. The machine has compact structure with short time from filling to sealing. And complicate sealing forms can be completed. b. It is guaranteed that there is no pollution during the filling process. The parts in the machine that contact the materials are all made of 316L stainless steel materials and complete polishing treatment is carried out on the contacting surfaces. c. High filling accuracy. The machine adopts reliable piston type quantitative filling valve, which is provided with convenient and reliable adjustment of the filling volume and high filling accuracy. Page 4 of 39

6 Figure 1 Schematic Figure of Main Machine 1. Electric Box 2. Hopper 3. Frame 5. Main Transmission Haft For Sealing 6. Tube Feeding Part 7. Profiling Lifting Head 8. Mechanical Hand 9. Filling Nozzle 10. Filling Volume Adjusting Hand Wheel 11. Motor Page 5 of 39 2

7 d. Easy assembly and disassembly of filling assemblies. The bucket valve body and piston filling head etc. can be rapidly disassembled and it is easy to carry out cleaning, disinfection and sterilization. e. During the filling, the filling nozzle can be extended into the tube, so as to ensure effective filling and prevent the sealing quality from being influenced as a result of material adhesion on the tube wall. f. The air blowing device is additionally installed. The filling head adopts the combined blow-out and cut-out filling mode so as to prevent the sealing quality and filling volume being influenced as a result of long wire drawn out by the materials of high viscosity. 3. Multifunctional sealing structure with easy adjustment The two-side folding, three-side folding and saddle-shape folding etc. different folding forms of aluminum tubes can be conveniently and accurately adjusted according to requirements of users. 4. The operating parts of mechanical hand completely adopt fully enclosed ball bearings, and the upper and lower sliding shafts on the machine table surface adopt linear bearing and self-lubricating system so as to avoid pollution. 5. The automatic filling & sealing machine adopts frequency conversion step less speed adjusting system, and the operation implements coordinated linkage control so as to achieve a higher production speed. The pneumatic control system is provided with precise filter with stable pressure of certain amount being maintained. 6. The movement system is allocated with safety clutch, which can effectively realize protection for fault overload. Page 6 of 39

8 7. Beautiful appearance and easy to be cleaned With beautiful appearance and compact structure, the machine is elaborately made by adopting stainless steel polishing, and its table surface is easy to be cleaned without any dead corner, which are fully in accordance with GMP requirements for medicine production. 5. Equipment Transportation and Installation 1. Transportation and Placement It is transported by wood pallet and forklift. Select a flat and dry indoor place, after the filling & sealing machine is stably placed and unpacked. Adjust the base bolts to level the main machine. The installation plan is as follows: Machine bottom corner Cold water inlet Cold water outlet Power interface Air supply inlet Tube bucket Main machine Power distribution cabinet Operator 2. After it is unpacked, please check the followings: Check if the machine is in accordance with your order according to the instructions. Check if there is any damage or cut that may influence the use caused during the transportation. If the above problems are found, please Page 7 of 39

9 immediately contact the sales department of our company for a proper treatment. 3. Installation of tube bucket Install the tube bucket onto the main machine and adjust the position of the tube bucket, which shall be kept vertically upward with nuts tightened. 4. Allocation of power supply The equipment adopts a 3-phase 380V four-line or a 3-phase 220V AC power supply. The user shall make sure there is reliable grounding when connecting it with the power supply, so as to guarantee personal security. 5. Allocation of air supply The equipment adopts an air supply of Mpa. The air supply allocated by the user shall be stable and the air displacement shall be not less than 0.6m 3 /min so as to guarantee the reliable operation of cylinder and achieve a precise filling effect. 6. Safety Notes 1. Before using the machine, please clean the surroundings. There shall have no dangerous articles or other foreign matters. 2. The machine is provided with protection of safety door. After the door protection functions, the machine will be stopped when the door is opened. It is strictly forbidden to operate the machine without starting the door protection, or else, accidents may take place. 3. There is high voltage inside the electric control box of the machine. Page 8 of 39

10 Unprofessional or untrained persons are forbidden to open it. 4. Make sure that the machine body is reliably grounded before the machine is operated 5. The operator shall pay special attention to the parts where safety warning marks are labeled on the machine body. 6. It is strictly forbidden to open the back cover of casing at the transmission part when the machine is operated, or else, personal injury may be caused during the operation. 7. Parts that do not conform to the machine performance can t be additionally installed and the machine can t be modified. Otherwise accidents may take place. 8. In case of emergency, please press the red emergency stop button and eliminate the malfunction in time. If it is necessary to restart the machine, make sure that the malfunction has been fully eliminated. The main drive system of the machine is located at the bottom of the machine table and is closed by a stainless steel door with a lock. When adjusting the filling volume, a special person (an operator or a maintenance technician) shall be designated to carry out the adjustment. Before restarting the machine, make sure that all the doors are fully closed. 7. Operation Procedures 1. First check if there is any abnormal article on the surface of the machine. Page 9 of 39

11 2. Check if the aluminum tubes and materials are in good condition. 3. Open the electric control box, switch on the power switch and turn on the general key switch and main machine switch. 4. Turn on switches for filling, color code, cleaning and tube feeding. If it is necessary to count, please also turn on the counting switch. 5. If there are heat preservation and stirring systems, please turn on the heat preservation switch and set the temperature required for heat preservation on the heat preservation and heating control meter. And then turn on the stirring switch. 6. Turn on the air pump switch or switch on the air supply. Adjust the pressure adjusting valve, and make sure the numbers displayed on the air pressure gauge is the set air pressure (the air pressure value is generally MPa). Press the emergency stop button to reset, press the inching switch, and then restart the main machine. 7. The machine shall be operated by qualified person after being trained. Others can t operate the machine randomly, or else, there may be the danger of human injury and machine damage. 8. Carry out idle operation for 1-2 minutes every time before filling. Check the operation status of all parts of the machine, which shall realize that the working status shall be stable with steady running and without abnormal noise, the adjusting devices shall function normally and the instruments and meters shall work reliably. Page 10 of 39

12 VIII. Operations of Touch Screen 1. Turn the combination switch to the position 2. Turn the key clockwise to turn on the power supply. At the time, the power indicator lamp will be on and the human-machine interface will be on. The main menu will be displayed (figure 8-1). Click OPERATION button to enter into the operation window (figure 8-2). Figure 8-1 Figure 8-2 Click MAIN MENU button to enter into door protection control window. When the door protection is on, during the normal operation of the machine, if the door is suddenly opened, the machine will immediately stop its operation and the touch screen will indicate that the door is not closed (figure 8-3). Page 11 of 39

13 Figure 8-3 Figure 8-4 Touch NEXT to enter into the window for adjusting coder parameters (figure 8-4). If the materials are thin with higher viscosity, we can adjust the parameter values of fill on, fill off and blow on, so as to solve the problem of wire drawing of filling nozzle. Touch DEBUGGING OPERATION button on the main menu to enter into the window for adjusting inching operation (figure 8-5) and carry out manual operation. Figure 8-5 Figure When there is any malfunction in the transmission mechanism, the safety switch at the bottom of the machine will be triggered, and the overload window will be displayed. Please cut off the power supply Page 12 of 39

14 and eliminate the malfunction before restarting the machine (figure 8-6). 8. Basic Adjustments 1. Install the five mechanical hands according to the dimensions on the installation figure of saddle-shape folding. Adjustment of the first mechanical hand 1. Adjust the eccentric shaft on the internal and external mechanical arms to make the two mechanical arms vertically at the center of the cup seat (refer to the following figure 1). Adjust the internal and external mechanical claws to make the interval between the internal and external mechanical claws at about 0.5mm. (refer to the following figure 2). 2. Note: The following adjustment is made by referring to the 5mm folding width of finished aluminum tube. The height of the two mechanical claws shall be the one where they flatten the tube tail for 25mm (refer to the following figure 4). The insertion board shall be adjusted to keep a certain distance with the concave and convex hinges (refer to the arrow indicated in the following figure 3). Page 13 of 39

15 Adjustment of the second mechanical hand 1. Adjust the seat for external mechanical hand to make its bottom parallel to the bottom of the mechanical arm (refer to the arrow indicated in the following figure). Page 14 of 39

16 Note: The adjustments shall begin from this position and during the adjustment, the position shall be guaranteed to be unchanged. 2. Adjust the eccentric shaft on the internal and external mechanical arms to make the two mechanical arms vertically at the center of the cup seat (refer to the adjustment of the first mechanical hand for details). Adjust the internal and external mechanical claws to make the interval between the internal and external mechanical claws at about 0.5mm. (refer to the above figure). 3. Rock the pulley manually to raise the lifting shaft to the highest point. Adjust the positions of the insertion board and mechanical arms according to the following figure. Pay attention to the arrow direction. Page 15 of 39

17 Note: The steps 1, 2 and 3 shall be synchronously operated. 4. Confirm the height of the rotary table according to the length of the aluminum tube (4mm is recommended). Page 16 of 39

18 5. Working state: During the operation process of the folding claw at 0-90, the external mechanical hand will not move. During the rotating process of the folding claw at , the upper wall of the external mechanical claw and the inner wall of the folding claw will make a parallel movement with an interval of 2mm between them (refer to the following figure 1). At the time, the folding claw will have a transient pause, and the external mechanical claw will continue to move. At the same time, the lifting shaft will continue to descend until the lowest point. From figure 2, we can observe that there is an interval of 2-3mm between the external mechanical claw and the folding claw. Only in this way, can it be guaranteed that the external claw will not block the tail of the aluminum tube (refer to the following figure 3). The folding claw will continue its rotation and the external mechanical claw will draw close to the inside to flatten the tail (refer to the following figure 4). Thus, the whole folding action is completed. Note: When the lifting Page 17 of 39

19 insertion board descends to the lowest point, the roller shall keep a certain distance with the mechanical arm. (as shown by the arrow in figure 2). Adjustment of the third mechanical hand 1. Please refer to the second mechanical hand for adjustment. Page 18 of 39

20 Adjustment of the fourth mechanical hand 1. Adjust the eccentric shaft on the internal and external mechanical arms to make the two mechanical arms vertically at the center of the cup seat (refer to the adjustment of the first mechanical hand for details). Adjust the internal and external mechanical claws to make the interval between the internal and external mechanical claws at about 0.8mm. 2. Adjust the internal and external mechanical claws to make the internal mechanical claw be about 0.5-1mm lower than the external mechanical claw (refer to the black arrow indicated in the following figure 1). 3. Adjust the height of the insertion board. When the insertion board descends to the lowest point, make the folding shaft at the center of the internal mechanical claw (refer to the white arrow indicated in the following figure 2). Page 19 of 39

21 Adjustment of the fifth mechanical hand 1. Adjust the eccentric shaft on the internal and external mechanical arms to make the two mechanical arms vertically at the center of the cup seat (refer to the adjustment of the first mechanical hand for details). The clarity of the printed code granules can be adjusted by M6 screws on the internal and external mechanical arms. Page 20 of 39

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23 9. Adjustment of Automatic Tube Feeding System Schematic Figure of Tube Feeding Part Page 22 of 39

24 1. Tube bucket 2. Rotary shaft 3. Locking handle 4. Right fender of tube bucket 5. Pentagonal nut 6. Handle 7. M8 screw 8. Left support 9. Stainless steel turning plate 10. Adjustable side fender 11. Adjustable fender 12. Joint bearing 13. Pull rod 14. Turning plate 15. Retaining plate of turning plate 16. Turning plate base 17. Tube feeding fender of turning plate 18. M8 screw 19. Right support nut 20. Linear bearing 21. Right support 22. SI32*65 cylinder 23. Tube fender support 1. Basic adjustment of integral height Loosen screws 7 and 18, turn handle 6 to adjust the integral height to the required one, which shall make that the turning plate of the tube feeding device shall be 10-20mm away from the cup seat at its bottom when the turning plate turns upwards at an angle of Tube feeding device Change a suitable turning plate, adjust retaining plate of turning plate 15 to achieve different heights and adjust turning plate base 16 to achieve different angles. 3. Adjustment of height of tube feeding bottom board According to the height of turning plate, adjust the two screws at 3, so as to make the tube feeding bottom board be 3-5mm Page 23 of 39

25 higher than turning plate. 4. Forward and backward adjustment of tube feeding bottom board According to the position of turning plate, adjust the two screws at 4, so as to make the tube feeding bottom board be 3-5mm away from the center of turning plate. 5. Adjustment of adjustable fender According to the size of the tube, adjust the height of adjustable side fenders 10 and adjustable fender 11 and make the height 5mm higher than that of the tube. 6. Adjustment of stainless steel fender The fender is 5mm higher than the tube and its angle is about vertical to the tube feeding bottom board. 7. Adjustment of tube bucket outlet Adjust the height of fender 4 to make the outlet be within the height of 2-4 layers of tubes. 8. Adjustment of tube feeding First lower the fender 4 and block the tube bucket outlet. Unpack the packaging box for tubes and feed all the tubes in the box onto the tube bucket. Loosen the locking handle 3 to make the tube bucket 1 rotate backwards at a certain angle around the rotary shaft 2. Tighten the locking handle 3. Take out the packaging box. After Page 24 of 39

26 the tubes are arranged in order, loosen the locking handle 3 and turn the tube bucket forward. Tighten the locking handle 3 and open the fender of tube outlet. 9. Adjustment of tube fender support Turn the rotary table to the work station. Adjust the front and back tube fender supports to make the tube fender supports keep a distance of 5mm with the outside wall of the tube. After the above 9 procedures are completed, manually put the tubes into the tube feeding bottom board and carry out debugging again. Before connecting with the air supply to carry out automatic debugging for tube feeding, make sure that the tubes can be smoothly inserted into the cup seats. 10. Adjustment of Transmission Part 1. Tension adjustment of transmission triangle belt Loosen the fastening bolts at the motor base, and adjust the tension of triangle belt to be appropriate and then tighten the nuts. 2. Tension adjustment of chain Adjust the position of chain tension wheel to make the chain tension appropriate. 3. Adjustment of safety clutch If the spring pressure of safety clutch is too small, the clutch will be Page 25 of 39

27 released and the machine can t be normally started. Adjust the adjusting nut for spring of clutch to minimize the spring pressure which can make the machine normally started. In case of fault overload, the clutch will be automatically released and the main machine will stop its operation. The warning lamp will flash to give indications. At the time, cut off the main power switch, and eliminate the malfunction immediately. After the malfunction is eliminated, hold the handle on the pulley and rock the pulley to reset the clutch, and then restart the main machine according to the starting procedures. 1 Screw the round nuts in for 8-15mm, with moderate overload withstanding capacity. 2 When overloading occurs, the output shaft will be separated from the clutch sprocket wheel, which will contact the switch and the machine will stop its operation. Figure 10-1 Page 26 of 39

28 Schematic Figure of Transmission Part 1.Speedreducer pulley 2.Speed reducer 3. Output shaft 4. Steel ball 5. Clutch sprocket wheel 6. Copper cover 7. Pad 8. Compression spring 9. Pressure cover 10. Round nut 12. Disassembly and Cleaning The disassembly procedures and cleaning requirements for parts needed to be cleaned are described in this chapter. 1. Hopper Loosen the hopper screws on the filling valve body and remove the hopper. During the first time use, please clean the parts by using solution made of edible detergent and then flush them with clear Page 27 of 39

29 water, and finally scrub the internal wall with alcohol and make them dry in the air. 2. Filling nozzle body and filling nozzle Loosen the fastening screws on the filling head of filling valve body and remove the air pipe to disassemble the filling head. Then screw off the filling nozzle to clean the filling nozzle body and filling nozzle with the cleaning method same as the above. 3. Filling valve body Loosen the screws connecting the valve body and the cylinder to separate the valve body from the cylinder. Loosen the rapid installation ferrule of the valve body and remove the filling valve. Gently push out the spool shaft, and carry out the cleaning with the method same as the above. 4. Note: When removing the valve body and spool shaft, please do not damage the valve spool and collide with the internal cavity of valve. 13. Daily Maintenance 1. Machine body After work of each shift, the workers shall cut off the power supply, clean and wipe the filling nozzles, cup seats, rotary table, sealing and code printing clamp mouths with absorbent cotton dipped into medicinal alcohol to maintain all parts clean without dusts. Then, close the reinforced organic glass door. 2. Sealing part Page 28 of 39

30 The roller bearing on the mechanical arm and the radial ball bearing of supporting clamp rod shall be added with lubricating grease once every three months. 3. Scale structure The lubricating grease of the large table column bushing and scale structure shall be replaced once half a year and they shall be checked and oiled once a week. 4. Speed reducer Check once a week. If the oil level is lower than 1/2 of that as shown on the window, if it is lower than 1/2, please add 30# engine oil in time. 5. The main drive system, chain and cam plate located at the bottom of the machine table shall be checked and oiled once a week. 6. If the machine is not used for a long time, before restarting the machine, please check if the screws of all parts are loose, and tighten and adjust them if necessary. Check the lubricating conditions of all transmission parts. After all the inspections are completed, start the main machine according to the starting procedures. 7. Please refer to the following figure for the servicing and lubricating of the machine. Page 29 of 39

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32 14. Common Malfunctions and Troubleshooting Malfunctions Troubleshooting 1. Check if the safety emergency stop switch is locked. The cylinder has no action. The code alignment and detection of the aluminum tube are incorrect. 2. Check if the air supply switch is on. 3. Check if the single-direction signal valve is damaged. 1. Check the angle and distance between the photoelectric detector and the aluminum tube. 2. Adjust the sensibility of the photoelectric detector switch to be appropriate. 3. Check if the photoelectric detector switch is damaged. If damaged, replace the photoelectric detector switch. 1. Check if the flow control valve is closed. The filling volume is inaccurate or there is no material discharging. 2. Check if the rotary filling valve is opened. 3. Check if the hopper is provided with sufficient materials. 4. Check if all the connection places are sealed. The printed codes are not clear. 1. Check if the installation method of code granules is correct and if they are fastened. 2. The code granules are worn. Replace the code granules. Page 31 of 39

33 Pneumatic Drawing: PLC Wiring: Page 32 of 39

34 Page 33 of 39

35 Main Circuit Wiring Drawing: Page 34 of 39

36 Packing List of IMC-60B Automatic Aluminum Tube Filling & Sealing Machine No. Category Name Unit Piece Specification Remark 1 Main machine Set 1 2 Use instructions Copy 1 3 Product certification Copy 1 4 Packing list Copy 1 5 Technical documents Acceptance form of Copy 1 installation and debugging 6 Cup seat Piece 9 7 Hopper Piece 1 8 Tube bucket Piece Plunger pump Piece 1 Heating box Piece 1 Blender Piece 1 Purchased by customer Purchased by customer Purchased by customer 12 Accessories Ultrasonic wave Piece 1 13 Toolbox Piece 1 Purchased by customer 14 Seal ring Set 1 15 Dead wrench Piece 4 16 Flexible wrench Piece 1 17 Slotted screwdriver, Philips screwdriver Piece 1 for each 18 Inner hexagon wrench Set 1 19 Code granules Set 1 20 Grease gun Piece 1 Page 35 of 39

37 Inspector Packer Date of packing IMC-60B Automatic Aluminum Tube Filling & Sealing Machine Machine model IMC-60B Machine No. Ex-factory date Date of purchasing Acceptance suggestion of user Unit seal of user User s address Responsible of user person Contact phone of user PC Supplier Page 36 of 39

38 Note: After the product is inspected as qualified, the customer shall fill in the acceptance form of RGZF-60B automatic aluminum tube filling & sealing machine and send (fax) it back to the customer service center of our company for record. If it is not sent back, it will be deemed as waiver of guaranteed maintenance. Page 37 of 39

39 Product Certification Product name: Automatic aluminum tube filling & sealing machine Product model: IMC-60B Ex-factory No.: Lobe Pump Manual Operation The product has been inspected as qualified And is allowed to leave the factory. Inspector: Date of inspection: Page 38 of 39