Quick mould change Do you change your moulds still the old way or with QMC? Quick mould clamping systems, ejector couplers, mono & multi couplers, mould changing solutions, UK inspection units & mould storage systems EAS Quick Mould Change System Reduces Manufacturing Cost Quick Mould Changes Systems lower manufacturing cost by reducing change over time. Frequent mould changes allow inventory to be reduced and provide faster response to customer requirements. EAS provides the following QMC solutions: Clamping Multi-Couplers Ejector Couplers Mould Handling Pre-heating With These Solutions You Can Achieve: Increased Machine Productivity Reduced Labour Cost Inventory Reduction Increased Flexibility Faster Response Improved Safety Resulting in lower manufacturing cost for you… Step-by-step Automation QMC Solutions can be applied in a series of cost effective steps. First you will need to analyze the complete mould change process step by step to identify where down time losses are occurring. Moulds that are used most frequently are your best candidates and provide the best return on investment. These moulds should be dedicated to a specific machine or group of machines. Ask EAS … For the best solution for your application. For a Return on Investment calculation. This analysis will identify where you should start applying QMC solutions. In most cases, clamping will be the first step to reducing mould change time. Quick clamping systems are not only faster, but also safer, as tool set up people no longer need to climb into the machine or under the mould to clamp up. For the complete SMED solutions from one global source. EAS offers you the most complete range of clamping solutions Content: Chapter: Clamping systems and ejector systems 1.1 - 1.9 1 Manual and automatic multi couplers 2.1 - 2.2 2 Mould change tables and cars 3.1 - 3.10 3 Service units and storage systems 4.1 - 4.3 4 1.1 Adaptive manually operated clamping systems p. 6-7 1.6 Electro permanent magnetic clamping p. 16-17 1.2 Adaptive hydraulic mould clamping systems p. 8-9 1.7 Ejector couplers p. 18-19 1.3 Mould change options (vertical) p. 10-11 1.8 Retrofit packages p. 20-21 1.4 Mould change options (horizontal) p. 12-13 1.9 Vertical presses and QMC p. 22-23 1.5 Integrated hydraulic mould clamping systems EAS Engel p. 14-15 1 Clamping systems and ejector systems bridagesystems manuel Adaptive, manuallySystemes operated de clamping Application examples Horizontal mould change a simple adaptive manual clamping solution Machine side: A clamping adapter plate is mounted on each platen. The clamping adapter plate is drilled to fit Europmap mounting plattens The manual bayonet clamping systems consists of a clamping adapter plate that is bolted to each platen using existing Euromap threaded holes. On the stationary side of the mould the existing locating ring is replaced by one of our bayonet centering adapters. The moveable side of the mould will also require a bayonet centering adapter. When loading the mould into the machine the stationary side bayonet adapter is pushed into the stationary clamping plate. The mould is located on the machine platenlocating ring. The mould is locked in place by a simple 53 degrees rotation of the lever. The machine is closed and the process is repeated on the moving side. The systems are suitable for moulds that weight up to 2 t and injection moulding or rubber moulding machines up to 250 t capacity. The clamping adapter plates are 17 or 22 mm thick with centering ring sizes of 100, 110, 125 and 160 mm. The manual system does not require mould standardization other then mounting of the bayonet adapter rings. Bayonet adapter rings are also available for tools with insulating plates. EAS Manual Clamping Solutions for SPI Platen Standards Manual clamping solutions are available for SPI machines with multiple ejector bar holes. These systems utilize a rack and pinion to rotate the lock ring to clamp the mould in place. The SPI manual clamp systems are equipped with removable handles. SPI clamping plates have a thickness of 1" inch. Bayonet adapter rings are available in a variety of configurations. spi machines Mould side: Moulds can be easily fitted with bayonet centering adapters A simple adaptive clamping solution for new or existing injection moulding machines and other applications. euromap machines 1.1 EAS can also supply simple roller systems with manual clamping for horizontally loading moulds. A clamping adapter plate is mounted to each SPI platen Systemes de bridage hydraulique Adaptive hydraulic mould clampingadaptatif systems All these cylinders can be ordered for several backplate heights and mounting screws sizes. the ideal solution for automated qmc systems The WS series clamps utilize an wedge system, which allows a greater tolerance on the back plate thickness. internal Clamps come equipped with 2 proximity switches to indicate the clamped and unclamped positions. This series of clamp also requires standardized mould back plates. Clamps are available in the following capacities: 80, 200 & 350 kN. mod / wod / nod series A typical quick clamping system consists of 4 or more double acting hydraulic clamps, which are mounted to both platens. The clamp plungers are angled at a 5 degrees to provide a self-locking feature. Pressure does not have to be maintained for the clamps to remain locked providing additional safety during the moulding operation. EAS offers two series of self-locking wedge clamps: MOD/WOD/NOD series with the 5 degrees plungers and the WS series, which uses an internal, wedging feature. Both series clamp on flat back plates and come equipped with 2 proximity switches to indicate the clamped and unclamped positions. The MOD series is the metric version for use on Euromap standard machines and feature metric mounting patterns and BSP oil connections. The WOD series is the imperial version for use on American SPI standard machines and feature imperial mounting patterns and SAE oil connections. The NOD series is available for the Japanese market requirements. The back plates of the moulds that are used with these series of clamps must be standardized because the clamps will be fixed to the platen. Clamps selection is determined by dividing the opening force of the machine by the number of clamps. Example: A machine with an opening force of 800kN (80 t) would need 4 clamps per platen, each with a 200kN (20 t) capacity or the MOD/WOD/NOD 2010. Clamps are available in the following capacities: 15, 30, 60, 110, 200, 400 & 1200kN. Standard temperature range: 60º C (140º F) High temperature seals and proximity switches available on request. ws - series Hydraulic clamping is the ideal solution for more automated QMC requirements. Suitable for new or existing injection moulding machines from 50 to 10,000 tonnes capacity. 1.2 Mould change options Vertical load mould change solution with fixed clamps Vertical load mould change solution with, movable clamps. Clamps are moved manually or with hydraulic cylinders. Vertical load and rotate fixed clamp solution 10 Vertical load mould change Vertical load mould change is the most common method of loading moulds into the machine. For this method the hydraulic clamps are positioned vertically between the tie bars on both platens. Slide plates and mould guides on a cylinder Clamping on the fixed side On the fixed platen 4 clamps would be mounted with guides, slide plates, tie bar protectors and mould stop locator. The mould slides in behind the mould guides and is positioned by the mould stop locator. The clamps can then be activated and the mould is clamped on the fixed platen. The movable platen is then closed and the movable platen clamps are then activated. The mould is now securely clamped. verticla loading 1.3 Centering rings are not required when using standardized back plates. Manual movable clamps Movable clamps Movable clamps can be used when fully standardized back plates are not feasible. MOD/WOD/NOD series clamps can be made movable in T-slots. This movement can be accomplished manually or automatically using a pneumatic or hydraulic cylinder. When done automatically the clamp sensor will determine if the clamp has reached the back plate. The cylinders are mounted on long T-nuts for accurate movement in the T-slots. It will still be necessary to standardize the back plate thickness at the clamping points as well as the height from the base to centerline if a mould stop locator is used. Vertical Load & Rotate Large moulds are often wider than the tie bar gap but must be rotated between the tie bars when loaded vertically. For this requirement the MOD/WOD/NOD clamps are positioned horizontally between the tie bars. Support ledges with a centering device position and center the mould accurately. Drop and rotate solution with safety latches (the mould on this machine is just for testing) 11 Options sur les changements de options moules Mould change Horizontal load mould change with non powered rollers Horizontal load mould change with powered roller transfer 12 horizontal mould change utilizing a mould change car or table When moulds are to be changed horizontally, clamps are positioned horizontally between the tie bars. The platens are equipped with rollers that allow the mould to roll into the press from a mould changing cart or table. Horizontal load clamp system with multi-couplers on a 1600 t machine Pre-rollers are used to support the mould between the safety gate and the edge of the platen. Mould stops accurately position standardized moulds in the machine. Centering cylinders position the mould when back plate length is not standardized. All systems include mould guides on the stationary platen and safety bars on the moveable platen. This prevents the mould from falling if the clamps are inadvertently retracted. These solutions require standardized mould back plates horizontal loading 1.4 Horizontal loading of a 40 t mould from a change table into a 2500 t machine. The system included pre-rollers, centering cylinders, MOD 4010 clamps and multicouplers Horizontal loading with powered rollers. A powered roller system is an alternative method for transferring the mould from the change cart or table into the machine. It replaces a telescopic push/pull device. Powered roller system on a 500 t machine The mould change cart or table and the stationary platen are equipped with powered rollers while the moveable platen has non-powered rollers. The powered rollers allow the mould to be changed more quickly than telescopic push/pull devices. They also allow easy change for machines that are on either side of the cart or table. 13 Système de bridagesystems hydraulique Integrated hydraulic mould clamping EASintégré Engel Clamping bolt mounted on the mould Machine side Horizontal loading solution with integrated clamping system 14 mounting in the machine platen, leaves the platen completely free Each mould would have the corresponding number of EEB clamping bolts mounted to each side of the mould. Clamping is achieved when the hydraulic cylinder moves the wedge on the end of the plunger into the matching wedge shaped slot in the clamping bolt. On small injection moulding machines only 2 hydraulic cylinders per platen are required for clamping. On larger machines (up to 2500 t), 4 hydraulic clamping cylinders per platen are required to handle the forces defined by Euromap 11 and VDMA specifications. On very large machine 8 hydraulic cylinders are required to insure trouble free clamping. Location of the clamping cylinders and clamping bolts must be standardized, and utilizes the centering ring for final mould location. The integrated hydraulic system can be applied to any new machine where the platens can be easily modified to accept the system. These platen modifications do not make it applicable for retrofit to existing machines. The integrated system keep the platens free eas engel system The hydraulic cylinder with the wedge and the clamping bolt The integrated hydraulic clamping system (Engel System) is mounted to the sides of the platen, leaving the platen face completely free of obstructions. Depending on machine size the mould is clamped using 2, 4 or 8 clamps per platen. 1.5 No standardization of the mould or back plates is required except for mounting of the clamping bolts. The full platen area can be used for larger moulds. For horizontal load mould change the mould is moved in over rollers and uses a mould stop for final position. For horizontal loading the mould must be standardized for the bottom to the centerline for proper alignment. The closing movement of the machine will push the clamping bolts into the platens. This movement can also be used connect the multi-coupler systems. To pull the clamping bolts out of the platens, the opening of the machine can be used or additional push cylinders can be mounted to the machine. Hydraulic integrated clamping systems with 2 proximity switches for clamp position feedback. 15 Electro permanent magnetic clamping Pressmag HP n Very suitable for larger sizes of injection moulding machines. (>800T) High flux generation, high forces on n smaller moulds Standard 310 mm( 12.2”) long poles n with resin sealing Up to 100° C.(212°F) Plate thickness 55 mm(2.16”). n n n Non magnetic filling plates outside the tie bar area with flux concentrating n 25 kN force per pole Pressmag SP n Very suitable for smaller sizes of injection moulding machines (<800T). n Small square/round poles, resulting in high forces within Standard 45 x 45 mm poles with stainless steel mesh seal, for cleaner and longer life. n Up to 150 °C (300°F) n Plate n 2,45 thickness 38 mm.(1.5”) kN force per pole Pressmag T n Suitable for all machine sizes n For zero residential magnetism n For alloyed steels n Up to 150 ºC (300 ºF) n Plate 16 limited areas and despite holes. thickness 55 mm (2.16 “) EAS PRESSMAG. A TOTAL RANGE For Every temperature and Application 1.6 Ideas come from EAS: Serving the Quick Mould Change (QMC) market for more than 20 years, EAS listened carefully to it’s customers to find better solutions for, YOUR QMC, JIT and SMED needs. The primary advantage of the magnetic clamping system is that it avoids the need for standardized back plates for vertically loaded moulds. EAS has optimized their new range of electro permanent magnetic clamping solutions which support: nincreased demand for full electric injection moulding machines nthe nsimple need for safe systems with sufficient holding force nsmaller extra safety device when required reduction in daylight opening Following the acquisition of the Pressmag “know-how” from Braillon - the original inventor of the electro magnet - EAS optimized it’s range of magnetic clamping systems by using both the benefits of the square pole design and the long pole design for the right application for you, our customer. The EAS solutions: n For small sizes of injection moulding machines (<800T) it is important not to lose much daylight opening due to thick magnetic plates. But at the sametime maintain the required clamping forces, despite ejector holes. For these reasons we developed the small 45 mm square pole design (but round at the surface) with only 38 mm (1.5”) plate thickness, the PRESSMAG SP and n for larger sizes of machines we optimized and standardized the PRESSMAG HP system working with standard long poles, resulting in high magnetic flux concen- tration with superior clamping forces. The thickness of these systems is 55 mm (2.16”). n for alloyed steels and/or for complete demagnetizing PRESSMAG T and ASK FOR OUR EAS n for high temperatures till 250° C or 464° F the PRESSMAG HT. MAGNETIC CLAMPING BROCHURE www.easmagneticclamping.com UK 17 Ejector couplers Mould mounted part type MEM 18 Machine mounted part type MCE time saving automatic ejector coupler systems 1.7 The EAS ejector couplers include a floating design to accommodate larger misalignment between the ejector coupler and the male adapter, which is mounted to the mould ejector rod. Features: Designed to VDMA 24465 part 5 standards. Hydraulically operated, single acting design. Life expectancy of 2 x 10(6) cycles at 50% of specified forces on the ejector coupler. Two proximity switches to indicate coupled and uncoupled position. Floating design allows 1mm of misalignment correction. The ejector couplers can also be operated pneumatically at reduced forces. Please consult EAS for pneumatic applications. Available in 20, 50, 100 & 200 kN capacities. For machines with American SPI platen configuration EAS has designed SPI ejector couplers which can be used with the 1" and 2" SPI ejector patterns without platen modification. Available in 1" or 2" diameter sizes the SPI ejector couplers simply push together, connecting the machine ejector to the mould ejector when the mould is loaded. When the mould is to be removed the ejector couplers are hydraulically pressurized to release. (WCE 10 can also be operated pneumatically) Our WCE 52 ejector coupler features an optional proximity switch to provide a confirmation signal to the machine controls. Extension rods are available on request and are designed for the specific machine application. The oil inlet is located on the end of the adapter rod. spi machines Ejector plate and rods on an injection moulding machine euromap machines In addition to mould clamps, multi-couplers and change systems some moulders require connection of the ejector system on the machine to the ejector system on the mould. The time consuming manual connections of the ejectors can be replaced by a simple automatic coupler system. Features: Sized for 1" and 2" knockout holes in the SPI platen configuration. Single acting design with hydraulic operation. Please consult EAS for pneumatic applications. 19 Ensemble pour machines Retrofitexistantes packages 20 FOR retrofitting existing machines 1.8 Retrofit solution with control unit and satellite boxes europe When the hydraulic clamps can not be powered by the machine tool hydraulic system, an independent pump and valve packages can be installed to provide the hydraulic power requirements. These pumps are often used on retrofit systems. Another advantage is that when the machine is down, the mould change can still take place as the pump unit and controls are independent of the machine. For the MOD- and WS -series of clamps, a mobile pump unit can be used for several machines as hydraulic pressure is not required when clamped but only at the time of the mould change. EAS have experienced installation crews to install these systems. Satellite box SBL-14 and SBR-14 These boxes collect proximity switch signals from the hydraulic mould clamps. SBR-14 for 4 clamps, SBL-14 for 4 clamps plus the ejector coupler. EAS offers retrofit QMC packages for existing injection moulding, compression moulding, thermal forming machines. Retrofit packages include: Adaptive Clamp Options Manual Clamps Hydraulic Clamps Magnetic Clamps Manual Multi-couplers Automatic Multi-couplers Ejector Couplers Hydraulic Valve packages (when hydraulic clamps are required) Hydraulic pump units (when we can not use machine tool hydraulics) PLC System Control Packages (when machine controls are not utilized) america Retrofitted machine Control unit PCU-10 This central operating panel has a PLC control, a key switch and enables you to control all clamping, ejector and if needed multicoupler functions. EAS can also offer installation support 21 Presses et QMC Vertical verticales presses and ASK FOR THE COMPLETE EAS QDC BROCHURE Mould carrier equipped with MOD type clamping cylinders and mould lifters. The mould is loaded by means of a manual mould change car. MOD wedge clamps were integrated in a specially designed ring for this special "Ringwalz" machine to produce automotive wheel frames. Due to the self-locking feature of this clamp, hydraulic pressure is not required after clamping or during the rotational movement of the ring. 22 in a quick and simple way Adaptive hydraulic clamps: Self-locking clamps type MOD Ledge Clamps type MLC T-slot Pull Clamps type MHC T-slot Clamps type MTC Travelling Die Clamps type TDC Permanent electric magnetic clamping systems product range As well as changing moulds quickly on horizontal injection and die cast machines, EAS can also change moulds quickly on all your vertical injection presses, compression presses, rim presses, mould carriers and other special application presses. EAS offers complete range of products and solutions to solve these problems in quick and simple way. 1.9 Integrated hydraulic clamps: Three Position Swing Clamps type MTR Swing Clamps type MSR Pull Cylinders type MPR The EAS Engel wedge clamps Mechanical clamps mounted on a special plate with spring loaded mould lifters and an isolating plate as well as a set of pre-rollers make this mould change on this Duroplast press a simple job. The pre-rollers are used for several presses by installing mounting hooks onto each press and moving the rollers from press to press. Die lifters: Spring loaded or hydraulic ball or roller die lifters for lifting and moving moulds & dies over the lower bed of the press. Mould change car for 2x25 t moulds to suit vertical mould carrier. The upperbed on this car rotates 180 degrees. MOD type clamps are used in the mould carrier. Pre-rollers: Pre-rollers for simple loading and unloading of dies & moulds in vertical presses. Mould & Die change cars 23 2.1 Manual multi couplers p. 26-27 2.2 Automatic multi couplers p. 28-29 24 2 Manual and automatic multi couplers 25 Manual multi couplers Simple and quick leak-proof connections of several water, air, oil and electrical circuits. EAS can provide you with a complete range of mono couplers as well. ASK FOR OUR EAS COUPLER CATALOGUES complete solutions from one source Mono & Multi Couplers EAS Europe B.V. De Hooge Hoek 19A 3927 GG Renswoude Holland Tel.: +31 (318) 477 010 Fax.: +31 (318) 477 020 [email protected] 26 Quick mould change systems Mono couplers Manual multi couplers Automatic multi couplers 2.1 This is an example of how fluid connections are often done, resulting in inefficient cooling, leakage and high scrap rates. The leak-proof EAS manual multi couplers are available in standard versions with 6 and 12 mono couplers. A variety of hose connection sizes and configurations are available for the mould half multi couplers. These high quality leak-proof water couplers can also be combined with air, hydraulic and electrical connectors to provide quick connections for all of the moulds utilities. Here is an example of the correct way of connecting several fluid circuits, without the risk of leakage or misconnenction. When used in conjunction with a good water treatment system, EAS multi couplers will reduce scrap and improve the quality of your production. Two standard manual multi couplers with 12 water connections, a special manual multi coupler with 5 electric connectors for signals and heating purposes and one special manual multi coupler for hydraulic core pulling connections are mounted on these 40 t moulds. The fluid and electrical connections are done within 3 minutes and without leakage of water or oil, which keeps the area very clean. A simple parking station is provided to hang the machine side multi coupler during mould change, avoiding coupler damage. With these coupler solutions, fluid and electrical connections can be made in a few minutes while keping the floor and the system clean. EAS can also supply a complete range of open and closed multi couplers which are completeley interchangeable with a leading competitive brand. We can also supply a variety of interchangable mono couplers some well known brands. CONTACT EAS FOR MORE DETAILS. A manual mullti coupler with several electrical connectors for heating and sensor signals. A standard 12 connection multi coupler, with size 12 (1/2”) water connections is used for the cooling circuits. A park station is used for hanging the manual multi coupler during mould change. These multi couplers solutions were implemented on five 1300 t machines. 27 Automatic multi couplers EAS multi couplers include the following types automatic couplers; For vertical loading of moulds Designed for moulds with many connections. With one or two moving docking cylinders to connect circuits independently of moulds and machine movements. For horizontal loading of moulds Similar to vertical loading except the mounting of the multi couplers is at the side of the machine. 28 simple, leak proof and fast connection of all your fluid and electric connections 2.2 Multi couplers can be used with different EAS couplers. Most applications use our leakproof self locking couplers type CQF and CQM, where the two multi coupler halves are locked together by each individual mono coupler. These couplers are available from size 6 to size 37 up to 900 l/min and for hydraulics up to 200 bar pressure. Special connect under pressure couplers are also available. This 2700 t injection moulding machines with horizontal loading, has standardized multi couplers on the movable and fixed side of the machines. Connections for cooling water, hydraulics for core pull cylinders and electric for heating and signals, are automatically connected and disconnected. This connection takes less then 30 seconds. All couplers feature the leak proof couplers, keeping floor and envirement clean. The advantage of self locking couplers: Self locking couplers contain the separating forces which occur when pressurized. By containing these separating forces within the body of the coupler we are able to reduce the stress on the coupler plate and cylinders. The other advantage with our CQF/M couplers is that if the mould is not in the machine, each coupler can still be connected for testing purposes. Because of the leak proof design we can combine water, air, hydraulic as well and electric connections into one automatic multi coupler. EAS also offers standard VDMA multi couplers. The number, position and arrangements of energy connections for automatic changing of injection moulds are specified and standardized according to VDMA 24464 and Euromap. This multi coupler system for horizontal loading connects water and electric connections trouble free in less than 20 seconds. Another advantage of these multi couplers is that misconnections are being made any longer, which reduces the amount of bad products. Large size 37 mono couplers are part of the multi couplers on this machine to connect leakproof large cooling lines. This in combination with heating oil connections and electric connections results in a total mould change time of less than 15 minutes in combination with hydraulic clamping and a vertical mould change by means of an overhead crane on this 2300 t machine. Fast, safe and clean. 29 30 3.1 Manual mould handling systems p. 32-33 3.6 Production cells p. 42-43 3.2 Battery driven Mould change cars p. 34-35 3.7 Rail guided mould change cars p. 44-45 3.3 Mould change tables p. 36-37 3.8 Air floating mould change car p. 46-47 3.4 Mould change tables for two moulds p. 38-39 3.9 Customized solution p. 48-49 3.5 Mould change tables, positioned between two presses p. 40-41 3.10 Pre-heating station p. 50-51 3 Mould change tables and cars 31 Manual mould handling systems 32 a simple horizontal way of changing moulds 3.1 Transferring the mould into the machine can be done manually or must be powered in depending on the weight of the mould. When the mould is light enough, manual transfer is practical. EAS offers the following solutions: Our manual mould change car for one mould of max. 800 kg. A manual car is used to transport the moulds from the storage area directly into the machines. The adjustable height feature uses a hydraulic hand pump and cylinders to raise and lower the bed. The car can accommodate one 0,8 t or two 0,5 t moulds. When the car arrives at the machine it is positioned to allow the existing mould to be manually pulled out of the machine. To support the mould between the cart and machine a set of bridge rollers are manually lowered. Once the mould has been removed the car is then positioned to allow the new mould to be manually pushed into the machine. The bridge rollers are then raised up out the way and mould is transported back to the storage area. EAS can offer different solutions depending on mould size and space limitations. Cars can be configured for side load or end load operation depending on the plant layout. Both configurations speed the mould change process. Our manual mould change car with 2 x 500 kg moulds. The moulds are pushed and pulled manually. 33 Battery driven mould change cars 34 flexibility, speed and easy to handle 3.2 When the moulds are too heavy to be transported manually, a battery powered car with hand controls can be the solution. These cars can be equipped with variable height roller decks to accommodate different size machines and storage system levels. Manual or powered push-pull mechanisms are available to transfer the moulds in and out of the machine or storage system. These powered transfer mechanism can be operated electrically or with air. 1 x 20 t with a combination of electric drive and air cushion floating for exact positioning in front of the machine, storage and inspection unit. Mould locks keep the mould from moving on the roller deck when the car is in motion. These cars handle one or two moulds with a combined weight of 25 t and come equipped a battery charging system. A two station mould change car can complete a mould change in less then 5 minutes when used with the press mounted roller and clamp system. When docking the car to the machine is difficult due to space limitations, EAS can supply a combination battery powered drive and air cushion car. For normal transport the battery drive is used. Once at the machine where space and maneuverability are a problem, the air cushion system is connected to the air supply and the car is easily floated into the exact position for loading. 2 x 3 t with an electric drive, air cushion positioning, an air driven push-pull device as well as a pre-heating station to heat up the mould outside the machine. 1 x 7 t with height adjustment but with powered transfer of the moulds over the rollers. 1 x 2 t with height adjustment and powered transfer of the moulds 1 x 2 t with height adjustment of 400 -1700 mm and electric push-pull device. 35 Mould change tables 36 for small and large moulds up to 200 ton weight 3.3 Single station mould change tables dedicated to an injection moulding machine. They are used when horizontal loading is required and moulds are changed infrequently or space is not available for two station mould change tables (see the next pages for multi station tables). These tables can use a manual or powered transfer mechanism depending on mould weight to load and unload the machine. The powered transfer can be equipped with an automatic push button control. On an Italtech 2500 t injection moulding machine EAS delivered the horizontal hydraulic adaptive clamping systems and a mould change table for moulds of maximum weight of 40 t. Guides on the table allow the crane driver to easily position the large mould in a simple way on the table. An air driven push-pull spindle device moves the mould in and out the machine. All water, hydraulic and electric connections are made with manual multi coupler systems. A Windsor 3000 t injection moulding machine is equipped with an adaptive horizontal hydraulic clamping system, an ejector coupler, automatic multi couplers and a mould change table for one mould of maximum weight of 35 t. The operator controls manually the different steps of the mould change. When using a single station change table you must first pull the mould from the machine and remove it from the table by overhead crane or fork lift truck. The new mould is then positioned on the table roller deck. The new mould is then pushed into the machine. These tables are used in conjunction with clamp and roller systems in the press (see page 12 & 13). The time required to do a complete mould change is depending on the size and weight of the mould. For example, a 40 t mould could be changed in less then 20 minutes. A table for 1 x 20 t mould with on one side the rollers with mould guidings, while on the other rollers moulds with different dimensions can be placed. This table has a fixed operation panel. This table also features two guides to enable the crane operator to position the mould easily on the table. 37 Mould change tables for two moulds Step 1 Step 2 Step 3 38 mould changes within minutes instead of hours Automatic mould change table for two moulds of max. 8 t each. This 800 t machine is equipped with hydraulic clamping system with rollers and with automatic multi couplers. A mould change takes place in less then 4 minutes and this system had a return of investment of 6 months. 3.4 Mould changes with a two station mould change table are faster then a single station mould change table because the mould is pre-staged on the table. Additional time can be saved by pre-heating the mould on the table. When changing a mould the mould in the machine is pulled on the empty station on the table. The table is then shuttled to position the new for loading. The new mould is then pushed into the machine. EAS provides powered transfer mechanisms which load from one side of the table or both sides of the table. Powered roller transfer is also available. This system utilizes powered rollers on the table and in the press to provide the fastest method of changing moulds. When mould change tables are used with 2 presses they increase your flexibility to run smaller production batches and reduce inventory. Side load systems increase safety for the operators because the mould is always supported and guided during the change. Mould change tables can be equipped with Programmable Logic Control (PLC) system which allows manual, semi-automatic or fully automatic operation. Automatic operation requires interfacing with the machine controls, and they are most often applied on new machines. Mould change table for two moulds of max 2 x 15 t, with an overhead push-pull device. This table features a pre-heating station with automatic multi couplers connections and was placed next to 800 t machine and a 1300 t machine. This mould change table , which can handle two 20 t moulds, has been fitted with a pre-heating unit; this allow pre-heating or the moulds outside the machine, so that valuable production time is not lost by heating the moulds while it is in the machine. Integrated multi couplers ensure automatic connection of all liquid and power supplies. Mould change tables are often equipped with a hydraulic power unit to power table movements as well as clamping, ejector couplers and multi couplers. On this 1000 t machine this table for 2 x 10 t moulds enables the operator to change moulds within 6 minutes. Each mould position features a telescopic push pull device for a fast transfer into the machine. At the end of each device is a pneumatic mould gripper to connect the push pull device to the mould automatically. Each mould need to be equipped with an adapter. 39 Mould change tables, positioned between two presses 40 mould change tables increase your flexibility, speed and safety 3.5 When using a mould change table betwen two injection machines you will improve your return on investment because the table is suporting two machines instead of one. This provides greater flexibility and faster changeover. EAS has implemented solutions with overhead push/pull devices, telescopic push/pull devices to load from both sides of the table as well as powered rollers. Powered rollers provide the fastest changeover because you do have wait for the push/pull device to travel into the machine. At this application a mould change table was placed in between two 2700 t injection moulding machines and is able to carry two 40 ton moulds. The moulds are loaded and unloaded on the table by an overhead crane. The table is equipped with pre-heating multi couplers, allowing the new mould to be heated prior to its movement into the machine, saving hours of unproductive time. At this application EAS selected an overhead transfer mechanism, which is mounted over the table and on the two machines. Each mould is equipped with two connection bars, mounted on top of the fixed side of the mould. With this solution a mould change can be done within 10 minutes. Note; If no overhead crane is available to load and unload the moulds on the table, the table can be equipped as a rail guided car. This table-car brings the moulds then to storage positions where several moulds can be stored. The moulds are equipped with standardized mould backplates. The fluid and electric connections are well organized and being connected by automatic multi couplers. Three 3000 t machines are configured with mould change tables in between. These powered roller mould change tables can transfer a 40 t mould into either machine at the push of a button. This provides speed and flexibility to the moulding process. EAS equipped the machines with powered rollers and clamping systems. EAS installed the complete system including platforms, stairs and mould change table control systems. The operator has acces to the top of the table form the platforms. Safety gates prevent people from walking on the table during the mould changes. 41 Production cells 42 For your complete automated production 3.6 Completely automated production cells can run very smal batches before changing over for the next run. These 2, 3 or 4 station change tables include pre-heating features and change moulds automatically. The moulds can be loaded onto the table by overhead crane or fork lift truck by opening the safety gate. The EAS production cells consist of clamping systems, ejector couplers and multi couplers on the machine and the multiple station mould change table with pre-heating system, all operated by PLC controls and on board hydraulic sytem. A fully automatic production cell with pre-heating station working with a 250 t injection moulding machine. EAS can also provide standardized mould back plates, mould side ejector coupler adapters and multi couplers. In most applications we work closely with the machine manufacturer to interface cell controls with the machine controls. A 150 t machine with a 2 way 3 position mould change table, pre-heating, multi couplers, hydraulic adaptive clamping and an ejector coupler. The pre-heating equipment is stored under the table and can be easily reached. 43 Rail guided mould change cars Mould change car travels within rows of machines and storage systems and pre-heating stations, changing to both sides of the car. 44 Mould change car to pick up moulds from the storage and to bring to one or more machines. Quick, safe and simple for moulds up to 200 ton 3.7 A further step towards automation is the installation of a rail car system to serve one or more injection moulding machines in a complete line of machines. 2 x 20 t car with height adjustment This usually means a complete reorganization of the plant and is most often done at new plants. The mould change car transports the moulds to and from the storage and or pre-heating stations. Unlike the mould change tables, the cars are not equipped to activate the requisite clamping and energy coupling operations. The cars can be battery powered or by an overhead power rail or by a cable trolley; in most cases the option is determined by the rail length and the normal frequency of mould changeovers. The cars are equipped with positioning devices for exact positioning along the machine or at the storage rack. They can be equipped by a manual or an automatic connection for the machine interface. The mould change device can load one side of the car or to both sides of the car in case the car travels in between rows of machines. Economy versions are equipped with spindle push/pull devices. More advanced cars are equipped with telescopic push/pull devices with automatic mould grippers. 2 x 40 t car in between 7 machines For safety purposes, each mould roller bed is equipped with a mould lock, which holds the mould on the car during transport along the machines. Safety bumpers, acoustic or light signals can be part of the car. The cars can be operated manually, semi automatic or completely automatic. The operator can either walk along with the cars or drive on the car from an operator platform. For different sizes of machines the car can be equipped with height adjustment. Loading and unloading of the moulds can be done from the storage systems or by an overhead crane. The storage systems can also be loaded by an overhead crane or by a fork lift truck. Mould change times for 40 t moulds can be accomplished in 10 minutes with these solutions. 45 Air floating mould change cars "System Aerogo” Air floating cars actually float on air film like a hovercraft and are therefor very flexible in moving around pillars or in restricted areas and can carry very heavy loads. 46 Easy movements of heavy loads 3.8 Air floating cars actually float on a thin film of air like a hovercraft whih provides great mobility in restricted areas. They can also carry very heavy loads without special floor reinforcement. A 110 t mould is transported from its storage system to the injection moulding machine or inspection unit. This customer, a producer of large plastic container, had no overhead crane available for such heavy weights and this solution enables them to change these moulds within 35 minutes. The push pull mechanism is a simple spindle device, which pushes or pulls the moulds in or out the large twin machine. An air floating car can be in interesting alternative to rail guided mould change cars. They easily move very have loads (up to 200 tons or more) in tight spaces while providing greater flexibility in plant layout then a rail system. The floor must have the cracks filled, be sealed, and level for the best performance. A suitable air compressor is required with an appropriately sized air hose. For greater range without several connections points, an air compressor can be placed on board the car. Noise level is surprisingly low. The upper roller deck is the same as a rail guided cart and features the same style of transfer devices, guides and mould locks. They can be loaded from a mould storage rack or by overhead crane. Air floating cars can be easily positioned in front of the machines with docking rails and locked to the machine. They can be controlled by a pendant control panel or by radio control. Air powered drive wheels control the speed and direction of the cart while the cart is moving. Space is very limited around the machines at this automotive supplier, two air floating cars for 2 x 20 and 2 x 15 t moulds are used to change these moulds in less then 15 minutes. The push /pull changing device can change the moulds to both sides of the car, which brings even more flexibility and speed. For extreme heavy moulds as at this container manufacturer EAS installed this air floating system in combination with storage systems, a 3400 t and a 6000 t injection moulding machine as well as an EAS inspection unit. The car can handle up to 150 t moulds and the change over time is less then 30 minutes. Air floating solutions can be very attractive for smaller mould handling requirements. It can also be combined with an electric drive system to travel longer distance. The operator can walk behind or even sit on board. Contact EAS for very creative solutions to your mould handling problems. 47 Customized solutions 48 easy movements of heavy loads 3.9 Special presses or other unusual circumstances lead sometimes to inventive solutions by EAS as the picture on page 48 shows. Because no overhead crane is available at every machine EAS designed this electric driven car to lift and lower moulds up to 2 t over and in the injection moulding machine. The vertical lifting stroke is 3000 mm and the horizontal stroke is 1500 mm. Ask EAS for your applications. For a range of vertical mould carriers, producing different internal part for a well-known car manufacturer in Germany, the space in front of the mould carrier was very limited. A special designed electric driven car on rails was developed to overcome these difficulties. The car can carry two moulds of each 20 t and the upper bed can turn 180 degrees. The mould sequence is therefor as follows; the car arrives with the new mould on the car, it docks on at the press. The existing mould is pulled from the machine onto the car, then unlocks and drives back two meters where the upper bed is turned 180 degrees. The new mould is now brought to and into the machine with a total mould change time of 10 minutes. A well-known Italian car manufacturer developed a very special injection moulding machine to produce car bumpers. The requirements were; faster, more flexible, reduce labor cost, reduce energy consumption, reduce floor space and optimize the production process control by automation. The mould change cars are having the following features; two way two direction travel with one guiding rail a 65 t load bearing capacity A floating upper bed table permitting easy self centering of the mould with the upper platen Compact size Control by means of a remote push button station A floor installed carriage guiders, mono rails and side tracks with crossing for two way movement Change over time for 1 mould in less then 10 minutes EAS developed together with Krauss Maffei in Germany a very fast moving mould transport table. Due to the manufacturing method the 6 t mould needed to be moved over a distance of 3000 mm in less then 5 seconds. This short timeframe is including acceleration and deceleration of the heavy mould and mould bed. EAS found the solution with the help of air cushions, normally used on our aircushion mould change cars, but now used to float the mould bed and the mould over the smooth and flat table frame. 49 Pre-heating stations 50 Save hours on your expensive production machines 3.10 In addition to the use of time saving automatic clamping and multi coupler systems, pre-heating moulds outside the machine can drastically reduce mould change over down time. Once clamped in position, with the energy circuits connected, a preheated mould is ready for instant production. This pre-heating can be done by a separate pre-heating station or by integrated pre-heating on the mould change car or table. Dependant on the degree of automation involved, such a station can be equipped with manual or automatic multi couplers and the requisite temperature controllers. This separate mould pre-heating station is used to preheat 20 to 40 t moulds out side the press. Integrated pre-heating station on a mould change table with automatic multi couplers equipped with leak proof hot oil couplers and electric connections. Electric and hot oil connections for pre-heating the mould. 51 4.1 Inspection units p. 54-55 4.2 Mould turning units p. 56-57 4.3 Storage rack systems for moulds & dies EAS Lift p. 58-59 52 4 Service units and storage systems 53 Inspection units For moulds up to 3 t EAS offers the Optim 25 service units The standard units are all 1200 mm long, 580 mm wide and 275 mm high. The two turning platforms are 350 x 500 mm. Optionally the units can be placed on a higher table for easier access or if you have other requirements such as clamping solutions, you can discuss these with your EAS partner. 54 simple and safe maintenance of your expensive tools 4.1 A further stage in the automation of your injection moulding plant is the installation of an inspection unit. This rationalizes the inspection and servicing of moulds, superceding a variety of slow and sometimes hazardous methods involving jacks and levers or block-and-tackle. Equipped with hydraulic or magnetic clamping systems on fixed and movable plates, the inspection unit greatly facilitates the rotation and precise positioning of moulds for maintenance and repair work; either as separate halves or coupled tools. A German supplier of washing machines uses this inspection unit with two tilting platerns for 20 t moulds. The loading and unloading of the moulds is done by an electric driven and air floating mould change car. The unit can also simulate core pulling movements and ejector couplers movements. For a well known German manufacturer of plastic containers EAS equipped several large injection moulding machines up to 6000 t with an adaptive hydraulic clamping systems, an air cushion mould change car, several mould storage racks and an inspection unit for moulds up to 100 t. A small unit for moulds of 2 t and with tilting platen. The control panel can be move around the unit by the operator. Safety mirrors as well as safety mat are also installed on this unit. EAS supplies these units in several sizes up to 200 t mould weight. The units can be equipped with hydraulic cylinders to tilt one or two mounting plates 90 degrees. For safety reasons the units can be equipped with a safety mat, which stops all movements if somebody steps into the table and or with safety light curtains which also stops any movement if somebody comes too close to the unit. The unit can be equipped with a number of options; Additional hydraulic or magnetic clamping systems for automatic vertical or horizontal mould loading. U-shape backplates in order to be freely accessible from the back. Multi coupler systems, manually or automatically for preheating purposes and or for controlling and checking the core pull cylinders. Movable upper clamping systems for different sizes of backplates. Ejector coupler with ejector cylinder for simulation of ejector movements. Steps and stairs for better excess. Connection for machine control to simulate certain programs. Spotting capability up to 20 t. For large container production heavy moulds up to 110 t are being transported by an air-floating car from the storage into this inspection unit. Either the mould half or the total mould can be turned on one side of the unit. The back of the plate is open, allowing maintenance and inspection at the back of the mould. Hydraulic core pulling cylinders are actuated in sequence with the opening stroke. Easy and safe maintenance without a huge overhead crane enables this customer to deal with transport and maintenance of very large moulds, fast and 55 Mould turning units 56 Combination of a mould change car and an inspection unit 4.2 A special electrically driven mould change car for moulds up to 1700 kg is also used as an inspection unit. The car has also height adjustment from 950 mm towards 1300 mm and has an electric push/pull device to change moulds on vertical press. The platen on the car is also equipped with spring loaded mould lifters from the EAS QDC program. Away from the press the mould halves can be separated over a distance of 600 mm and each platen can be turned 90 degrees for maintenance. Mould change-inspection car. Electric driven and hand controlled. Max. mould weight 1700 kg. Mould push and pull device on both sides. Spring lifting die lifters in the platen. EAS can also supply mould turning or mould manipulators to turn your expensive moulds 90 degrees for transport or storage in a different way. This turning unit is for moulds up to 20 t and is remote controlled. EAS can supply these units up to 100 t mould weight. 57 Rack storage and lift systems for moulds or dies EAS offer a wide range of mould and die storage systems. These can be simple roller beds for horizontal mould or die storage systems or automated tool storage systems for 100 to 200 moulds or dies with several layers. They can be manually operated or fully automated. Single entry Double entry EAS LIFT HAND CONTROLLED PERMANENT MAGNET LIFTERS The EAS Lift utilizes state of art technology to make a powerful, lightweight permanent lifting magnet. Our exclusive Test Talon® feature allows an operator to safely test load feasibility and a deep “V” notch between the pole shoes allows greater stability when lifting round stock. For details see: www. easlift.com (with shop) 58 Superglide tools need to be stored and in many cases this is away from the machines These horizontal mould storage systems are loaded and unloaded by means of electric driven mould change cars, on which either manual or automatically moulds are placed. Underneath the moulds is room for other mould related equipment. This electric driven mould change car for a large vertical press can bring the moulds far away from the press to a special mould storage area. The moulds can be stored left and right of the electric driven car. The driver has a camera and a monitor for exact positioning the car into the press. Changing and store moulds between 10 and 20 t is in this way simple, fast and safe. 59 rack systems rack systems storage V ertical storage If rail guide mould change cars, air float mould change cars, electric driven or manual free moving are being used one car easily load and unload the moulds from these handling systems onto horizontal mould storage systems or pre heating systems. These horizontal storage systems are equipped with rollers, a mould stop and a mould locking device and can placed near the machine or in other parts or the plant. In case of a railguided system the storage racks can be placed on both sides of the rails. H orizontal Our glide-out racks are easily handled by one person and are equipped with an automatic locking system for operational safety. Three versions are available, the standard single entry, which can be extended up to 63% in one direction, double entry shelves which can be extended up to 63% in two directions and to complete the range, the superglide, a two-stage extending system which gives 100% access to the shelf area. It is a modular system and may be added to, or adjusted as required and consists of a starter bay and extension bays. Easily reachable with overhead crane. Automatic systems can also be supplied for up to 200 moulds or more. Treat your expensive tools with great care and store them safely. 4.3 EAS Addresses Worldwide Italy W134 N4949 Campbell Drive Menomonee Falls, WI 53051 United States of America Tel.: +1 262 783 7955 Tel.: +1 800 664 7086 Fax: +1 262 783 9799 Tel: +39 335256569 Tel: + 39 3409343820 Fax: +39 039 9719504 E-mail: [email protected] easchangesystems.com E-mail: [email protected] easchangesystems.com E-mail: [email protected] The Netherlands, Belgium and Luxemburg EAS Europe B.V. De Hooge Hoek 19A 3927 GG Renswoude The Netherlands kvk: 30173173 Tel.: +31 318 477 010 Fax: +31 318 477 020 E-mail: [email protected] France, Belgium, Maroc, Tunesia EAS France EAS MED S.r.L. Vimercate Germany North, Denmark, Poland EAS Europe B.V. Klaus Hermann Röttges Hof 11 45473 Mülheim/Ruhr Germany Tel.: +49 208 76720-91 Fax: +49 208 76647-1 Mobil: +49 171 444 7950 E-mail: [email protected] easchangesystems.com Czech Republic, Slovakia Kuboušek Pressmag engineering office 429, avenue Léonard De Vinci ZI Alpespace F 73800 Ste Hélène-du-Lac. Tel: +33 479650410 Fax: +33 479650686 Kuboušek s.r.o. Lidická 1937 370 07 Ceské Budojovice Tel.: +420 386 102 110 Fax: +420 386 351 819 E-mail: [email protected] EASchangesystems.com E-mail: [email protected] Internet: www.kubousek.cz Spain Bereiker Germany South, Austria, Europe South-East, Central Europe Croatia, Hungary and Romania Pol. Ind. de Goiain San Andrés 1. Pabellón 5 01170 Legutiano (ARABA) Spain Tel.: +34 945 465 460 Fax: +34 945 465 461 E-mail: [email protected] Brazil HDB Representacoes Ltda. Rua Martiniano Lemos Leite, 30 Cotia/SP, CEP,06705-110 Tel.: +55 11 4615 4655 Fax: +55 11 4703 3000 Switzerland Mega-Plast Kunststofftechnik Rohnenstraße 14 Postfach 20 8835 Feusisberg Switzerland Tel.: +41 44 784 5788 Fax: +41 44 784 75 01 E-mail: [email protected] EAS Weißdornweg 4b 70599 Stuttgart Germany Tel.: +49 711 47623-3 Fax: +49 711 47623-43 E-mail: [email protected] easchangesystems.com United Kingdom EAS 8, Meadow Close Marshalswick, St. Albans Herts AL4 9TG United Kingdom Tel.: +44 1727 855 758 Fax: +44 1727 842 823 India Selplast Corporation India Norway Maskin K. Lund AS Storm Martens 307, Harekrishna Complex Pritamnagar, Ashram Road 380.006 Ahmedabad India Tel.: +91 79 657 9674 Fax: +91 79 657 9271 Stalfjaera 11 P.O.Box 21 Kalbakken 0901 Oslo Norway Tel.: +47 22 900200 Fax: +47 22 900201 E-mail: [email protected] e-mail: [email protected] Sweden AMO Produkter AB Kyrkvägen 1 Sollentuna Holm Gård 19272 Sollentuna Sweden Tel.: +46 08 626 8045 Fax: +46 08 626 8047 New Zealand Machinetech Ltd. E-mail: [email protected] E-mail: [email protected] Finland Eko - Form Turkey AKSOY Plastik ve Makine ltd. Box 83 00381 Helsinki Finland Tel.: +358 1 023 92000 Fax: +358 9 560 74620 Kucukyali is merkezi, girne mahallesi, irmak sok E blok no 4 Kucukyali-Maltepe 34852, IstanbulTurkey Tel.:+90 216 5188333 Fax:+90 216 5188324 MOBIL:+90 532 2510298 Australia Fleming Plastics Equipment PTY Ltd. 20/32 Roseberry street P.O.Box 638 Balgowlah NSW 2093 Australia Tel.: +61 1300 730 736 Fax: +61 1300 730 739 Mob: +61 417 464 966 Internet: www.fleming.net.au China Gienkee Plas Centre 1221 HaMi Road ShaiHai P.C. 200335 Shanghai (200041) P.R. China Tel.: +86 21 62398170 Fax: +86 21 32100012 e-mail: [email protected] 112A Mays Road Penrose Auckland Tel.: +6496330071 Fax: +6496330072 E-mail: [email protected] www.aksoymakine.com Portugal AS Lda. Rua da Paz Nº 19 Bloco B, Marrazes 2400-404 Leiria Portugal Tel.: +351 244 854 675 Fax: +351 244 854 733 E-mail: [email protected] South Africa Engel 2 Fabriek Street Strydom Park, Randburg P.O Box 5459 Weltevreden Park 1715 South Africa Tel.: +117937011/2/3/4 Fax: +11 7923381 E-mail: [email protected] E-mail: [email protected] Korea Mico Myoungjin Co 173-260, Gajwa-dong, Seo-gu, Incheon, Korea (Zip.404-811) Tel.: +82 32 584 2008 Fax.: +82 32 576 3008 E-mail: [email protected] www.EASchangesystems.com www.easlift.com [email protected] EASA649 © 2007 EAS - Subject to change without notice USA, Canada Latin America & Caribbean EAS Mold & Die Change System Inc.
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