Beruflich Dokumente
Kultur Dokumente
Unibell Korea
Sep., 2007
HeaCo(Heat & Cool) Mold Temperature Control System
For the plastic injection molding process, the mold temperature should be controlled
in a uniform condition so as to produce stable end-products. The meaning of mold
temperature control is to affect considerable molding conditions such as outward
surface of the parts, electrical feature, residual stress, shrinkage rate, deformation
and dimension stability. The temperature of the mold is used to be adjusted upon
the specification of the plastic resin.
In general, it is a common sense on the plastic injection mold that there are cooling
water channels to cool down and heat up the temperature of the molds by means of
oil or water energy to keep uniform temperature cycle.
Depend on the specification of the plastic resin the working mold temperature shall
be controlled within the range of 60℃ ~175℃. In this regard, the temperature of
the mold should be lower about 10℃~15℃ than thermal deformation temperature of
the plastic resin.
In the meantime, there is a different and specific concept of mold temperature
control in the Heat & Cool Process against existing control system so far. A series
Heating Injection start
of this process is to go for injection after heating up the mold over the thermal
Temp. up finished
transformation temperature and to extract the part after cooling down the mold
Mold Temp. Curve
Temp. down
temperature below the dimension transformation temperature (ejection possible
temp.).
heating Cooling
형개시작
heating Cooling
If such a heating and cooling process failed to be executed rapidly within the
promised cycle time, there are serious productivity problems such as over cycle
Control
Heating media
supply
Cooling
water
blowing Heating media
supply
Cooling
water
blowing
time, gas generation and degradation of the resin for its longer time to stay melted
in the machine cylinder, which is actually a matter of difficult problem to be solved
Seq.
so far. Especially, some of the companies in Europe and the U.S. have been
Heating & Cooling Cycle sequence continuously studied for 20 years to find a way of quick heat-up and quick cool-
down technology in order to put to practical use, but they made poor progress.
HeaCo(Heat & Cool) Mold Temperature Control System
In fact, if they could get the quick heat-up and quick cool-down technology, the progressive effect of the result shall be so
much remarkable for the productivity, for it will be able to resolve the surface quality problem, which has been actually the
most serious matter on the plastic injection molding process in case of exterior parts. By this technology, additional
painting process will not be required any more, which will save the raw material cost and will get the high quality of the
exterior parts as well.
Such defective points as weld-line, flow-mark, unbalance of
surface gloss and transmission are essentials to do plastic
injection molding. It is simple to explain the main reason why
this kind of situation is essential to the molding parts. As for the
injection molding, the molten resin is generally used to be filled
into the cavity forming the fountain flow pattern. In review of the
Normal Molding Heat & Cool flow mechanism with a mold at the substantially lower
temperature than the melting temperature, the melted resin at
Can Not Find Out Weld Line with Heat & Cool
the front position is cooling down slowly and making frozen skin
layer. And the following plastic melted hot resin would enlarge
the skin layer to be longer stream and consequently the skin
PP+ long fiber Press Molding
layer could be gradually sticking to the inner surface of the cavity
wall. At the same time, solidification is beginning and the skin
layer is being cooled down while it is in the long enlarged status,
which will cause shear rate between the central flow-layer. The
difference which is occurred between shear rate and cooling
speed will cause the source of the defective quality. Especially,
due to the specific character of plastic material, the melting
Normal molding Heat & Cool viscosity of resin is quite rely on the temperature. And the flow
length to decide volume of flowing comes under influence of this
difference.
HeaCo(Heat & Cool) Mold Temperature Control System
Now we are going to introduce HeaCo System as the most efficient heating and cooling control system. This system
has been developed to obtain maximum heating & cooling effectiveness by using the minimum energy.
HeaCo(Heat & Cool) Mold Temperature Control System
67″ front mask 1. Generally speaking, in order to minimize the heating time, the temperature of
heating medium should high and the pressure also must be high. But, it is quite
hard matter to increase the pressure. In order to heat up the temperature up to
mold set temperature in a very short time, the temperature and pressure of the
using medium are so important factors. And in order to obtain and distributing the
regular temperature to overall skin-core of the mold, the instant flow speed of the
supplying heating medium should be maximum fast.
2.Obtained heating medium temperature from the HeaCo System will keep
basically 200℃ or higher and the pressure also start heating from 25kg/cm2 or
more. Therefore, we are sure that this system is much more profitable than any
other systems.
3. To make best use with high temperature and high pressure produced from
the system, we have developed a unique drain control system on the steam
outlet area and the effect has proved out.
Regarding the safety matter, at the moment that the pressure of steam is so
high, safety problem can be considered. According to the basic rule of
thermodynamics, if the steam has got discharged to the air and lost the energy
out, i.e. if the steam pressure has got down to the atmospheric pressure, the
temperature shall go down and then changed to water drops. In other words,
in the restricted volume, such steam energy, which has got generated for
simply heating up purpose, would not be enough to use.
HeaCo(Heat & Cool) Mold Temperature Control System
* Long heating time = heat up for surface with mold itself (Boilers)
It means that it is not possible to keep a necessary dimensional stabilities and to be avoided
from the warpage due to temperature deviation for 60” TV front mask .
HeaCo(Heat & Cool) Mold Temperature Control System
1. General Specification
Controller 100
Water purifier 1000 x 1000 x 1700
Dimension
mm HeaCo Main body 820 x 1850 x 1750
(W x L X H)
Controller 450 x 500 x 1600
Max. temperature ℃ 250
Steam 360/25
Max. pressure psi/bar
Water 1500/100
Heater 87.5
Electric Power kW Steam pump 3.2
Cooling pump 3.2
Steam Outlet EA 16 inlet/outlet
Minimum 4 kgf/㎠
Pressure
*At loading of water purifier, it must be above 3 kgf/㎠
City-water ----
Quality Level Below 300ppm
Consumption rate 3.0 tons per day
Compressed air kgf/㎠ Min. 6
HeaCo(Heat & Cool) Mold Temperature Control System
2. Utilities Specifications
Descriptions Data
Supply Pressure Min. 2.0~3.0 kgf/㎠
Flow rate 200 liter/min
Cooling water Inlet 2”
Supply Piping size
Outlet 1 ~ 2”
★ Use a clean water with no minerals for no-depositing of a scale
Quality
★ Install an additional “line-filter” if possible a particles may mix
2. Utilities Specifications
Descriptions Data
Supply output of free-contact pulse only
Interface Signal Heating start signal
Mold opening start , Cable No. X034
Input Signal to
HeaCo Supply output of free-contact pulse only
Cooling start signal
Injection start , Cable No. X035
Interface Signal Supply output of free-contact pulse only
★Injection start interruption
Output Signal to As mold temperature heat up to set temp., supplying the signal to IMM.
until get the output signal
IMM IMM start injection by the signal.
HeaCo(Heat & Cool) Mold Temperature Control System
3. Looks
HeaCo(Heat & Cool) Mold Temperature Control System
3. Looks Additional
Steam
Drainage
S1
Purge Manifold
HeaCo(Heat & Cool) Mold Temperature Control System
4. Transportation
When you are going to move the HeaCo unit to anywhere, please read on the application of
casters on the manual carefully before moving it out.
Do not handle the unit using an overhand crane but please use a lift truck.
Regarding the packing materials for the unit before shipment, it should be disposed in
accordance with the current laws.
5. Installation
Outdoor installation is prohibited . The unit must be installed in the room.
① Provide minimum 1 meter distance from the sides of unit for proper service and maintenance.
② After making a decision of the location, the level of the unit is to be adjusted by the height adjustment and then it
will be locked.
③ Make sure that there are 4 sets of height adjusters and please lock them up once again after level adjustment.
HeaCo(Heat & Cool) Mold Temperature Control System
6. Utilities Connection
① Cooling water supply:
In view of Steam Mold system, cooling water supply takes an important role. If it is not enough
to supply the cooling water in volume, at the first, the Cooling Water Pump in HeaCo system can be damaged so
easily as it will go for overload working. Cooling water will receive pressure to be sent into the mold for cooling
process and it will affect to the cooling time. Without supplying enough water, the cooling time shall be longer.
In case of bad quality of cooling water, too many calcium and of other substances included, this calcium material will
prevent air driven valve operation from the normal operating, which will cause shorter life than normal guaranteed life.
You may have to frequently clean the steam line/cooling line for the scale elimination. Accordingly, to manage the
water quality thoroughly could be the best way for the machine to keep longer life and to protect it from any defective
factors.
② Main Electric power connection:
HeaCo system has considerable capacity of heater and therefore careful preparation is required
according to the specification mentioned in this operating manual. Especially, it is noted that we use ceramic heater
band on the heater, which has specific function to draw up the electric power for an instant in order to get heat up. If
there are less electric capacity installed, it may cause overload heater and shorten the life, by which electrical
problems can be occurred. Enough electric power supply must be provided all the time.
③ City-Water supply:
In the HeaCo system, City-Water is used to get the steam. City-Water will be linked to Water
Purifier to be purified up to around 10ppm degree of purity. This purified water shall be provided to HeaCo system.
Here, the water pressure and water volume to be supplied will be very important factors. Less water pressure and
water volume will cause abnormal operation of the pump in the water purifier and will bring short life as well. Also, in
case of water drainage, on the water purifier, the water should be drained without any pressure. By the way, if there is
still holding pressure remained backward, it is not possible to drain out completely, for which filter life on the water
purifier might be shortened. If water quality is not in a good condition, place pre-treatment filter or water softener
before installing water purifier so as to provide pure water into the water purifier and as a result to keep long life of the
precise water purifier’s filter.
HeaCo(Heat & Cool) Mold Temperature Control System
City water
Purge- Manifold supply
1/2” min.3 kg/㎠
1/2”
Waste water
Drain line
3/4” 2” 1/2” 1”
Compressed Air supply
Cooling water In
Interface signal
With IMM
Connect to
the Purge- Manifold
HeaCo(Heat & Cool) Mold Temperature Control System
When heat-up start or cooling start relay signal is given to the system, you can check the interlock
signal connection situation so easily on the MENU bar of the screen. Heating lamp is ON while the
mold is heating up and Cooling lamp is ON while the mold is cooling down.
HeaCo(Heat & Cool) Mold Temperature Control System
OUT MANIFOLD
IN MANIFOLD
Drain On/Off Valve
MOLD
Steam Out Line
3/4” Piping
Water Purifier
Pump Specification
HeaCo(Heat & Cool) Mold Temperature Control System
After checking all the connections upon the above procedure, please make sure the following points.
① Check the purity of the water on the water purifier. By the purity sensing gauge equipped with the water purifier, please check
the value of the purity. It should be maintained lower than 15.0 ppm in order to supply the water into HeaCo system.
② Open the air supply manual ball valve, Cooling water supply valve and drain manual ball valve. Turn ON the main power switch.
③ Check out the direction of the cooling pump motor rotation. The rotating direction should follow the mark mentioned on the
pump (clockwise). Also, please open air drain valve a little which are located on the below of the pump and on the upside of the
pump. When the air drained out completely and water drained, then please close up the valve lightly.