Automatic production of insulating mat for electri

2022-09-23
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Automatic production of electric iron insulating mats from bulk molded plastics

through continuous innovation, abog has introduced special machines, peripheral equipment and automatic solutions for the processing of thermosetting plastics, so that thermosetting plastics and unsaturated polyester bulk molded plastics can be processed more effectively. The company adopts an automatic production system to produce an insulating pad for household electric irons, which proves that the production of BMC products can be automated

screw driven feeding device

in order to effectively feed BMC mixing ingredients, aberg developed a screw feeder, which can push the materials containing fibers into the plasticizing barrel by the screw and the parallel feeding device with a diameter of 300mm in the process of metering and processing. The feeding screw is driven and controlled by a servo motor

Figure 1, the insulating base of the electric iron

through the programming of the selogica control system on the allrounder injection molding machine and the regulation of the screw speed, the filling pressure of the material can be measured at the material inlet of the barrel to ensure that the material can be fed into the barrel at a constant pressure, regardless of the filling level of the barrel. The maximum speed of the screw is 5R/min. Therefore, the material can always be carefully fed into the barrel without damaging the fibers

the filling level of the storage tank can be monitored without spots, corrosion and other phenomena. Although the material can be filled into the storage tank at any time, when the material needs to be added to the storage tank again, it is determined by the indicator light and the information from the control system

in Figure 2, the BMC mixture can be continuously transported to the injection molding unit by using the screw propeller

with this new propulsion method, BMC materials can be sent to the processing section more carefully and conveniently. The processing section is transparent, so the selogica control system can be used to program and monitor the material loading device, so as to facilitate the management of the processing section. By monitoring the filling pressure in the plasticizing screw feeding chamber, it is ensured that a high standard of feeding quality can be consistently obtained, so as to achieve a highly accurate and consistent material measurement, which can be confirmed by small changes between measured batches

automatic production of insulating pads for electric irons

by integrating the upstream and downstream processing steps of injection molding into a production unit, the automatic production of BMC products can be realized, which can be confirmed by the mass production of insulating pads for electric irons. The production unit includes an allrounder 570 s injection molding machine and a six axis manipulator system, which is not only used for taking out parts, but also responsible for all downstream processing operations

Figure 3, the allrounder 570 s injection molding machine with screw propeller is mainly used for processing thermosetting plastics

this standard injection molding machine is equipped with a "thermosetting kit" for processing thermosetting plastics, which provides all necessary hardware and software as the standard configuration of the production unit. As for the control part of production, the selogica control system operates according to the processing program of thermosetting plastics, which has expandable functions, such as the function of exhausting or closing the mold under specific temperature conditions. Another standard configuration is a special barrel and screw equipped with a check valve for processing low shear adhesive bottom materials. Through the screw propeller, BMC mixed ingredients are continuously fed to the injection unit. The product is formed in a single cavity mold heated by electricity. The mold temperature is 140 ℃, and the cycle time is 60s. Through effective insulation measures, the loss of mold temperature is prevented. In addition, all post-processing processing of formed parts is also completed within this cycle, thus achieving high production efficiency

the grinding station with vacuum pumping device can remove the flash on the finished product. In order to obtain high-quality parts, the parts must be fully cooled to room temperature before removing flash. This can be achieved by a cooling station that can accommodate 10 parts at the same time with the increase of nickel ratio, which ensures that the cooling waiting time is within the required range. Using an image processing system, the flash condition of the product can be checked. Finally, through the placement system, the formed parts can be placed on a finished shelf with a space saving arrangement. The production unit is fully automated, without human operation, control and care

all operations of components are completely completed by the flexible six axis manipulator system. Based on the selogica user interface integrated into the manipulator control system, which has been tested in practice, the operation of the manipulator is very convenient. Like the programming principle used in selogica machine control system, the complex operation of the manipulator is also programmed based on this principle, that is, the operator does not need to have special programming knowledge to complete all this. For the machine installation technician, he can use the familiar graphic programming method that has been proved in the application of injection molding to compile all the motion programs of the six axis manipulator system without any external help

Figure 4 on the grinding station, a six axis manipulator moves accurately along the contour of the insulating pad,

so that the flash on the edge of the part is completely removed

the normal sequence of using the six axis manipulator to transfer the formed parts is: first take the parts out of the mold and put them in the cooling station, and then these parts become the formed parts that have been properly cooled. The transfer operation of formed parts is based on the principle of first in first out. Then, on the grinding station, a six axis manipulator moves accurately along the contour of the insulating pad, so that the flash on the edge of the component is completely removed. Then, the six axis manipulator will put the parts that remove the flash into the front end of the optical inspection station. In the subsequent inspection, the inspection system can judge the qualified products and unqualified products. According to the test results, the qualified products are sent to the finished product rack, while the unqualified products are put into the waste box. In a finished product rack arranged in a space-saving way, qualified products are carefully placed vertically if they are stronger

advantages of automation

in addition to integrating all downstream processes, the use of flexible six axis manipulator also makes the production process quite economical. Because the formed parts are cooled according to the principle of "first in, first out", and the post-processing operation of the parts also operates accurately according to the product outline, plus it can reliably separate the unqualified products, and it can carefully place the qualified products, all of which ensure that the final high-quality products can be obtained. The qualified parts after 100% inspection are carefully put into a finished product rack arranged in a space saving way. Using this production unit makes it possible to reduce the demand for manpower and greatly simplify logistics operations

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