EPS Single Minute Exchange of Die Shape Moulding Machine

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PART 1 Energy Saving

  • Steam System
  • Pipe System
  • Vacuum Cooling System

Steam System --- Low Pressure And Big Flow

l Smart Steam Control

l Sutuan machine equips single valve locator & digital proportional control.

l Adequate steam can be supplied in a short period of time reducing cycle time and steam consumption. Which provides excellent production condition.

Shape With High Temperature And Low Pressure

l Using multi-pipes, One with LVDT relied to the chamber. To have a more flexible control over the steam pressure

l

l Fusing begins at 90℃ and complete shaping will be achieved at 115℃. Forming pressure only 3-3.5 bar.

Steam System

l Close & 22MM Thick Copper Pipe

l 22MM thick Water Spray

l Cooling time 1s

l Aluminium Alloy Chamber: Save the cost of having multiple chambers $2,000-4,000

l Steam chamber with patent heat insulation coating reduce steam lost > 10%

l Equal & rapid steaming flow design,main steaming period 3~5s.

l Multi-spots heating perform most equal distribution of steam in the mould chamber.

l < 50s/cycle (Products thickness ≤ 250mm)

Pipe System

l Pipe Close To The Chamber

l The design of the valve inlet and outlet of each piping system is optimized by being close to the mold, thereby minimizing the energy waste and increasing the response speed.

l The water sprayer takes 1s

l Smoking De-mould,no water drop from mold.

l Clean&Nice working environment

l Heating room is not necessary.

Vacuum Cooling System --- High temperature demoulding

l Vacuum cooling enables high temperature demoulding, greatly improves production speed and reduces energy consumption.

l Mold temperature variation under vacuum cooling: 90°C

l Mold temperature variation under water cooling: 60°C

EPS Steaming forming temperature: approx. 105 °C

Water

20-100°C

335kj

Water-Steam

100-100°C

2256kj

l 7 times more energy saved by high temperature demould.

l Heat is taken away from inside products by vacuum cooling.

l Water content <5%,no additional oven drying needed.

l Multiple layers of stainless steel

l 15~20 times larger than ordinary

l (empty).

l Water vapor exchange

l Heated moisture air&Sprayed water&Stainless screen layout enable an efficient cooling.

l Featuring a high pumping capacity up to 600m3/h (360cfm).

l NASH 2BV5/6 liquid ring pump also condenses steam which increases its suction capacity.

l Half-size installation space

Siemens Vacuum Pump

l 20,000 hours no fault running,even under the toughest conditions.

l Efficient/save running,only a 22Kw central vacuum system is enough to support max 15 sets shape machines.

l Save more than 35% by unit vacuum cooling.

PART 2 Stable Quality Performance

l Control System

l Security System

l Hydraulic System

Control System

l International brand components

l Germany Gemü Proportional Valve & Pressure Sensor

l Siemens intelligent PLC Control System

l Italy Cosys Calibration Valve

l Siemens PLC control

l 15 inches industrial touch screen all in one machine

l WinCC embedded operating system

l Online big data management for customer's most efficient parameter setting.

l Remote Assistance APP

WinCC embedded operating system

Schneider Electric Switch

l Digital parameters to display

l Error alarm list & Maintenance Guidance

l Multi-colors running state indicator light

l Motor running state detection and protection.

Japan SMC Solenoid valve

Siemens PLC

Security System

Multiple hardware security protection interconnection system is used in combination with Siemens S7-1200 intelligent controller software security firewall system to ensure the safety of workers.

Hydraulic System

l Adopt high resolution digital encoder to control open and close die stroke, cruise speeds can be 300mm/s

l Mechanical, hydraulic and electrical triple chain safety protection.

PART 3 Quick Mould Change System

Unique structure, only 10-20 minutes to change the mold.The mold shift is fixed without personnel to enter in between the female and male mold to eliminate safety hazards.

One Touch Change The Mould

l Open framework design

l Advanced auto rod guide and fix system

l Mould change time < 5min

l Greatly reduces machine stop period, increase capacity.

PART 4 Reasonable Structure

Lock Mould Mechanism

Cancel mold clamping rod, reduce mold storage space, mold processing costs, parts costs, and reduce maintenance costs.

Increase the effective use area of the mold by 15%

l The whole frame adopts 16MM (high manganese steel Q345) welded combination

l The frame surface is treated by ball blasting, zinc and powder coating to improve antiseptic performance

Machine Frame

l Mold frame is constructed & supported by 4 main rods, which can be removed and replaced separately for maintenance, without disassemble the whole machine.

①Welding② Heating treatment ③Milling process ④Perforating ⑤CNC process ⑥Ball blasting ⑦Zinc coating ⑧Color painting ⑨Assembling

Reasonable Pipeline Layout of Steam And Compressor

l All butterfly valves and angle seat valves adopt German brand, large flow, closed-loop steam control system to ensure fast and stable steam heating, faster mold temperature rise, reducing significantly heating time, ensure quality.

Reasonable Pipeline Layout of Steam And Compressor

l Compact design, all control valves are as close as steam pipe, achieving fast and accurate steaming.

l Zinc spraying on steam pipeline for a longer service life.

Special Vertical Hopper

l Each drum equipped 24 outlets (DN25).

l Pressure maintain 2-4Kg / cm2 in drum for 24 hours without leakage, which is of great importance for EPP shape molding machine:

l No pressure drop during material transportation from preload pressure tank to machine hopper.

l Ensure consistency before and after actual production.

Specialized Vertical Hopper

l Photoelectric level sensor control, material shortage alarming and then autoshutdown, etc.

l Sealing mechanism is made by CNC machining center to ensure the accuracy of the mechanism and versatility of spare parts

l Multiple feeding options, dual-flow air reduces material blockage, well solved difficulty feeding in special-shaped products, and other problem. Achieved pulse feeding, vacuum feeding, pressurized feeding, gap feeding, etc.

PART 5 New Technology

Intelligent Big Data Management & Control System

All equipment in the factory can be integrated into APP & PC for

remote control, fault feedback, remote maintenance.

Robot Arms—Reduce labor cost and improve efficiency

Double robotic arms on machine and support with related parts.

Mainly applied for products requiring embedded parts and self pick-up.

Multiple Steam Injection Point

l Multi-spots(up left and right) heating realize fast,efficient and equal distribution of steam in chamber. Reduce failures in steaming large-size products.

l The equipment has its own chamber, and the chamber is equipped with thermal insulation board, which can effectively reduce steam loss. LVDT pressure control method is adopted for steam inlet: precise, fast and stable control of molding pressure fluctuation amplitude to a line, which can greatly improve product quality, reduce steam energy consumption and cost

LVDT(Linear Variable Differential Transformer )Control System

l The change of pressure control curve amplitude tends to be a straight line, accurately controlled at ±0.10Bar, and the transition is stable without pause impact.

l Stable temperature control curve, stable heating process, low pressure and large flow, lower steam energy consumption.

l Real-time pressure sensor feedback of molding air chamber pressure, accurate and timely data.

l Product rejection rate < 0.3%, effective control of product shape and size (deformation), pressure control accuracy, stability is to ensure stable product quality, energy saving, production efficiency and multi-product production key.

PART 6

ST Machine Advantages

Solution: Upgrading to ST QDCS machine(Quick die change system) which takes only 20-30 minutes to change the mould.

Details: Steam consumption has been reduced from 15 tons to 6 tons per ton raw material

l The factory uses 60 tons of raw material every month.

l Let’s see how much the steam cost each month:

l Before: 15*60*$36/ton=$32,400/month

l Now: 6*60*$36/ton=$12,960/month

l After upgrading,just the steam cost can save $19440 each month.

Products from company Hangzhou Sutuan Machinery Co., Ltd.