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Seminar on all electrical injection moulding machine main


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Seminar on all electrical injection moulding machine main

  4. 4. INTRODUCTION  The INJECTION MOULDING MACHINE is a type of machine in which we convert raw material (plastic) into desired shape by applying heat and pressure.  In this machine, Material is fed into a heated barrel, mixed and forced into a mould cavity where it cools and hardens to the configuration of the cavity.  In this process we are using thermosetting and thermoplasting both type of raw material.
  5. 5. HISTORY  Isaiah Hyatt invented the first injection molding machine in 1872.  In 1946, American inventor James Watson Hendry built the first screw injection moulding machine,  In 1983,Nissei Plastic Industrial Co. LTD introduced the first all-electric injection molding machine.  The MILACRON CORPORATION was the first injection moulding machinery manufacturer which is introduced ALL ELECTRIC INJECTION MOULDING MACHINE in 1985.
  7. 7.  The machine use less energy, have greater precision, accuracy and produce less than hydraulic machine  In this machine every function was controlled by a separate electric servo-motor (rather than hydraulics).  This type of machine have high efficiency factor just like power consumption.  This type of machine has not required any type of hydraulic system.  This type of machine has not use any type of induction motor for all sequence of an injection moulding machine.
  8. 8.  This machine saves 40-80% energy.  This type of machine has not required any type of machine cooling so it saves energy in compare to HIMM.  This machine has not required hydraulic oil so it saves money.
  9. 9. MACHINE SPECIFICATION  Injection system The injection system consists of a hopper, a reciprocating screw and barrel assembly, and an injection nozzle, as shown in Figure. This system confines and transports the plastic as it progresses through the feeding, compressing, degassing, melting, injection, and packing stages.
  10. 10.  The hopper Thermoplastic material is supplied to molders in the form of small pellets. The hopper on the injection molding machine holds these pellets. The pellets are gravity-fed from the hopper through the hopper throat into the barrel and screw assembly.  The barrel As shown in figure the barrel of the injection molding machine supports the reciprocating plasticizing screw. It is heated by the electric heater bands.
  11. 11.  The Reciprocating Screw The reciprocating screw is used to compress, melt, and convey the material. The reciprocating screw consists of three zones (illustrated below)  The feeding zone  The compressing (or transition) zone  The metering zone
  12. 12.  The nozzle The nozzle connects the barrel to the sprue bushing of the mold and forms a seal between the barrel and the mold. The temperature of the nozzle should be set to the material's melt temp.
  13. 13.  The servo motor A servomotor is a motor which forms part of a servomechanism. The servomotor is paired with some type of encoder to provide position/speed feedback. This feedback loop is used to provide precise control of the mechanical degree of freedom driven by the motor.
  14. 14.  THE MICROPROCESSOR CONTROL For the better accuracy of parameter, we used microprocessor based control system. To ensure consistency of quality of injection molded parts one has to look at the controls like pressure, speed, stroke, and temperatures. This is the repeatability of the product quality with close tolerance on dimension and weight throughout long production run.  There are some images of screen of microprocessor, which is easily define the work of its. For example –  Clamping data  Temperature data  Overview data  Mould data  Process monitoring data  Mould data  Main page of Microprocessor
  15. 15. This image shows all clamping data of process
  16. 16. This image shows temperature of all zones
  17. 17. This image shows the overview of full process
  18. 18. This image shows all monitoring data
  19. 19. This image shows that all data of mould
  20. 20. This image shows the main page of microprocessor
  21. 21.  Ball screw A ball screw is a mechanical linear actuator that translates rotational motion to linear motion with little friction. A threaded shaft provides a helical raceway for ball bearings which act as a precision screw. As well as being able to apply or withstand high thrust loads, they can do so with minimum internal friction.
  22. 22. Machine operation sequence  The mould closes and the screw begins moving forward for injection.  The cavity fills as the reciprocating screw moves forward, as a plunger.
  23. 23.  The cavity is packed as the screw continuously moves forward.  The cavity cools as the gate freezes off and the screw begins to retract to plasticize material for the next shot.
  24. 24.  The mould opens for part ejection.  The mould closes and the next cycle begins.
  25. 25. Cycle time in injection moulding  This image show the full cycle of injection moulding machine.
  26. 26. Materials for Injection Moulding  Acrylonitrile butadiene styrene (ABS)  Acetal  Acrylic  Polycarbonate (PC)  Polyester  Polyethylene  Fluoroplastic  Polyimide  Nylon  Polyphenylene oxide  Polypropylene (PP) **  Polystyrene (PS)  Polysulphone  Polyvinyl chloride (PVC)
  27. 27. ADVANTAGES OF ALL ELECTRIC INJECTION MOULDING MACHINE  These types of machines have not required hydraulic oil because it has no hydraulic system.  These types of machine have not required cooling and plumping of hydraulic oil.  All electric injection moulding machine have low noise level in compare to hydraulic injection moulding machine.  All Electric injection moulding machine eliminates the cooling equipments for the hydraulic system.
  28. 28.  Lower operating costs- Whether small or large, all- electric machines dramatically reduce operating costs, using 50% to 80% less power than equivalent hydraulic machines. Connected power requirements for an electric machine are only 25 percent of those of a hydraulic machine.  Accuracy, repeatability, and consistency- Electric machines are digitally controlled and mechanically driven. Their processes do not vary over time since they have no hoses to expand, no valves to potentially stick and no hydraulic fluid to heat up or compress. Molders often report that these machines produce good parts by the third or fourth shot and then run without attention until it's time for a mold change.
  29. 29.  Higher part quality. Electric machines turn injection molding into a more predictable operation. With a more consistent machine, the same process setup can be used repeatedly, without affecting part consistency or quality. For example, screw position for fill and pack is controlled with digital precision, eliminating over packing and greatly reducing molded-in stress.  These types of machines are fast compare to hydraulic moulding machine.  It has not required cool water for machine cooling.
  30. 30. Disadvantages of all electric injection moulding machine  ALL ELECTRIC INJECTION MOULDING MACHINE is too expensive in compare to conventional hydraulic injection moulding machine.  In this machine, we can use only virgin materials. This is a major disadvantage of ALL ELECTRIC INJECTION MOULDING MACHINE.  Its breakdown maintenance is too expensive because of its parts are so costly.
  31. 31. COMPARISION between AEIMM and HIMM  Hydraulic injection moulding machine is using large induction motor to drive pump but all electrical injection moulding machine using small motor to move each function of the machine.  The induction motor always has some load put on it due to pump but in AEIMM using of servo motor use energy only when they are running.  The hydraulic injection moulding machines have required hydraulic system but AEIMM have no hydraulic system.
  32. 32.  The hydraulic injection moulding machine has high maintenance but AEIMM has very low maintenance compare to HIMM.  In hydraulic injection machine need large amounts of power required to drive pump up to high pressure for inject or increased volume for charging but in AEIMM the servo motors are off during dwell times such as part cooling time.  Hydraulic injection moulding machine need cool water for machine cooling but AEIMM not required cool water for machine cooling.  All electric injection moulding machine are quiet…60db which is 20db lower compare to hydraulic injection moulding machine.
  33. 33. Maintenance of AEIMM  Maintenance – The activity carried out to prevent the occurrence of failure and activity carried out after failure to rectify the defect is called MAINTENANCE. Why Maintenance required - There are so many cause present, some cause are following –  Plant or Machine in any organization is expected to run continuously without any interruption during production period.  Interruptions are frequently felt on account of machine, breakdowns due to failure of machine parts / components.  There is always some loss of production on account of m/c failure.
  34. 34. Types of maintenance There are two types of maintenance – 1. Preventive Maintenance 2. Breakdown/Corrective Maintenance Preventive Maintenance- The activities, which are carried out to prevent the occurrence of failure are knows as Preventive Maintenance. PM is further divided in two parts- A. Direct Preventive Maintenance B. Indirect preventive Maintenance Breakdown Maintenance- The activities which are carried out after the occurrence of failures to correct the failures are knows as Breakdown/Corrective Maintenance.
  35. 35. The maintenance of All electric Injection Moulding machine  SENSOR Any sensor used requires a power supply and an amplifier. A sensor is driven by an input voltage. Usually called an “excitation” voltage. A resultant output signal is generated as the sensor responds to the monitored parameter. An amplifier is used to boost the output signal the output signal’s strength. Increased signal strength or amplitude is needed for recording capabilities. Sensors and electrical systems should be tested and calibrated before actual before actual use. Variances to occur between sensors of the same type. Sensors should be maintained at a “zero” reference. Electrical “drifting” destroys the accuracy of the information being obtained.
  36. 36.  Motors One method of applying the driving force to turn the screw is attached it to an electric motor. The available torque of an electric motor has a pattern of a 100% starting overload. Which corresponds to the higher torque requirements of starting with colder plastic material? Safety devices of varying degrees of effectiveness are used to prevent the overload from snapping the screw.
  37. 37.  Electric drives do not have independent speed and torque control. The speed is changed by gear trains, and because the input and output power area constant, a change in wither speed or torque will inversely affect the other. This relationship makes it difficult to find optimum molding conditions.  The electrical system has a high efficiency of approximately 95% compared to the 60 to 75% of the hydraulic system.
  38. 38.  LIMIT SWITCH A limit switch is a means of interfacing position or mechanical motion with the electrical circuit. The contacts are mounted in rugged enclosures and usually consist of one set of normally closed and one set of normally open contacts. They can be had in up to for pole configurations. The most common operator is rotating lever with a wheel at the end.. They are widely used on molding machines, being found in safety control circuits, low pressure closing, platen speed injection control and mold safety circuits.
  39. 39. Maintenance Schedule Daily Maintenance  Clean the machine thoroughly.  Wipe the toggles with a clean cloth till it is free of the accumulated grease and dust.  Check the nozzle area for melt accumulation and clean if necessary.  Check the piping of grease lubricating system for loose connections.  Check whether the feed throat temperature is maintained during running If found rising even with the water supply ‘ON’, check and clean the cooling ring
  40. 40. Weekly Maintenance  Check the grease pump for sufficient amount of grease.  Limit / Proximity switches.  Check safety devices.  Check nozzle centering.  Check for the tightness of connectors on IBED, PLC, Wiring terminals on the control cabinet, Linear Potentiometer plugs and Solenoid plugs.  Rear and front guard door Limit switches.  Nozzle guard Limit switch.
  41. 41. FUTURE The All Electric Injection Moulding Machines have a very bright future due to own accuracy, efficiency, consistency and repeatability. These types of machines have very low maintenance so it is a very useful. In other word it is future of whole plastic industries, which are related to injection moulding field. Its ability of power consumption is very profitable for a plastic industry because it saves 40- 80% energy in compare to conventional hydraulic injection machine.
  42. 42. Applications There is various range of injection molded product, some images are following-  This image shows various apps. Of injection molding process
  43. 43. This image shows daily uses thing which is made by injection molding
  44. 44. This image shows the sanitary products
  45. 45. This image shows bathroom thing
  46. 46. C0NCLUSION The All Electric Injection moulding Machine is very simple, fast, accurate and easy to use. All electric is primarily meant for the lowest energy cost, extreme reproducibility, narrow processing window for thin walled component in engineering polymers, prolonged accuracy and instant repeatability, high uptime, smaller shot size utilization, low emission, water saving, noiseless environment need, clean room necessity.
  47. 47. Reference  Injection Moulding Machine. Edited by – A.S. Athalye  Introduction to Plastic Processing techniques. Edited by – S. Sugumar  Injection moulding book Edited by – P.K. Sahoo.  