HyPET Operator Course

HyPET OPERATOR COURSE v1.0

Keeping our customers in the lead

Machine Manual

Safety Summary

Chapter 1

Safety Summary

The Safety Summary describes general requirements and conditions for safe installation, operation, and maintenance of injection molding equipment. Personnel must read, understand, and follow all safety precautions listed in the equipment manuals. Personnel must follow applicable industry and regulatory safety requirements for safe installation, operation, and maintenance of equipment.

1.1

Manuals Husky manuals aid in the safe and proper use of the machine, robot, and mold. The manuals provide instructions on installation, installation, operation, and maintenance. A separate Drawing Package includes parts lists and drawings. Personnel should review all manuals thoroughly prior to performing any tasks. Proceed with tasks only if all instructions are understood. Follow applicable workplace safety requirements. Keep manuals in a convenient location for future reference. Signal words are used in the manuals according to the degree of severity, and

Hylectric PET Injection Molding Machine

1.2

Safety Signs Safety signs clearly mark potentially hazardous areas in or around equipment. For the safety of personnel involved in equipment installation, operation, and maintenance, use the following guidelines: 1. Verify all signs are in the proper locations. Refer to the Drawing Package for details. 2. Do not alter signs. 3. Keep signs clean and visible. 4. Order replacement signs when necessary. Refer to the Drawing Package for part numbers. The table below describes safety symbols appearing on safety signs. Each safety sign could include a detailed explanation of the potential hazard and associated consequences. Safety Symbol

General Description of Symbol General – Warning

This symbol indicates a potential personal injury hazard. It is usually accompanied by another pictogram or text to describe the hazard.

[

Danger – Hazardous Voltage

Contact with hazardous voltages will cause death or serious injury. Turn off power and review electrical schematics before servicing equipment. Electrical cabinet can contain more than one live circuit. Test all circuits

Machine Manual

Safety Summary

Safety Symbol

General Description of Symbol Warning – High Pressure

Overheated water or steam may cause severe burns. Discharge pressure before disconnecting water lines.

Warning – High Pressure Accumulator Sudden release of high pressure gas or oil can cause death or serious injury. Discharge all gas and hydraulic pressure before disconnecting or disassembling accumulator. Warning – Hot Surfaces

Contact with exposed hot surfaces will cause serious burn injury. Wear protective gloves when working near these areas.

Warning – Slip, Trip, or Fall Hazard Personnel climbing on equipment surfaces may slip, trip, or fall causing injury. Do not climb on equipment surfaces.

Warning – Crushing Hazard

Contact with the rotating screw can cause serious crushing injury. Do not insert body parts into the feed t hroat opening while the machine is operating. Install a hopper or a direct feed system. Warning – Read Manual Before Operation

Personnel involved with equipment operation and maintenance should be


1.3

Qualified Personnel Only fully trained personnel should be permitted to operate, maintain, and service equipment. In addition, make sure: 1. Only one qualified person operates the equipment at a time 2. The area around the equipment is safe at all times.

1.4

Training Skilled personnel are required to operate and maintain Husky equipment. Contact a Husky Regional Service and Sales office to arrange training.

1.5

Guards And Interlocks Guards are provided where hazards exist. There are two types of guards: movable and fixed. Movable guards are interlocked to stop hazardous motion when t he guards are moved or removed. Fixed guards are not interlocked. Fixed guards must be installed and completely secured anytime power is applied to the machine. Before operating the equipment, make sure:

Machine Manual

Safety Summary

1.6.1 Performing Lockout/Tagout

Special Tool Required 1

Hydraulic pressure gauge suitable to 210 bar (3000 psi) with quick-disconnect fitting

Perform Lockout/Tagout using the following instructions:

DANGER! Electrocution hazard – risk of death or serious injury. Install danger sign at all isolation points and rope off the area around the machine. When live troubleshooting is required, do not work alone. Have emergency medical assistance nearby throughout the procedure.

WARNING! Hazardous voltages, high pressure fluids, crushing or impact hazards – risk of death or serious injury. Perform Lockout/Tagout procedure in accordance with local codes. After performing Lockout/Tagout procedure, allow 10 minutes for residual voltage to discharge to less than 50 Volts before performing any electrical procedures. Only qualified personnel should perform Lockout/Tagout procedure.


1 2

Figure 1-1

Manual Dump Valve Locations

1. Manual dump valve

2. Power manifold assembly

6. Turn off shutoff lever (5) on the air regulator (6) to turn off the air supply to the machine – refer to Figure 1-2. Attach a lock (7) and a tag (8) on the air regulator. 5

Machine Manual

Safety Summary

1.6.2 Removing Locks and Tags Remove Locks and Tags using the following instructions:

WARNING! Hazardous voltages – risk of death or serious injury. Perform Lockout/Tagout removal procedure in accordance with local codes. Only qualified personnel should be permitted to perform Lockout/Tagout procedure. 1. Check all power cables are properly connected. 2. Verify the danger zone around the machine is clear of all personnel before attempting to remove the lock and tag at the main disconnect switch. 3. The lock and tag should only be removed by the person who installed them. If the person is unable to personally remove the lock and tag, verbal instructions can be given to remove the lock and tag. The instructions must also include any specific measures required to return the machine to safe operating condition. If the person cannot be contacted, then a supervisor and a qualified technician who has a thorough understanding of the machine should perform the following checks: a. Check all isolation points to make sure that hoses, wires, and/ or systems are set to a safe condition. b. Verify that the danger zone around the machine is clear of all personnel. c. Remove the lock and tag only when both the supervisor and the technician agree that all systems are in order, and there is no potential for injury.


1.7

Safety Hazards Some common safety hazards associated with injection molding equipment are: 1. Mechanical (pinching, shearing, crushing) 2. High Pressure Leak 3. Thermal 4. Spray 5. Electrical 6. Noise 7. Gas, Vapor, and Dust Emissions 8. Slipping, Tripping, or Falling 9. Lifting.

1.7.1 Mechanical Hazards 1.7.1.1 Worn Hoses and Safety Restraints Regularly inspect and replace all flexible hose assemblies and restraints.

1.7.1.2 Cooling Water Hoses

Machine Manual

Safety Summary

1.7.2 High Pressure Leak Hazards 1.7.2.1 Hydraulic System Flexible hose connections and piping in hydraulic systems must be properly tightened to prevent the release of fluids or gases under pressure. Hoses must be inspected periodically for signs of sweating and/or blistering. Steel tubes should be tested using dye penetrant.

1.7.2.2 Skin Puncture Injuries High pressure hydraulic spray can penetrate human t issue and cause severe bodily injury. Seek immediate medical help in any event of skin puncture by fluid spray.

1.7.3 Burn Hazards 1.7.3.1 Hot Surfaces The mold area, ancillary mold equipment, and injection unit heating elements have numerous high temperature surfaces. At normal operating temperatures, contact with these surfaces will cause severe skin burns. These areas are clearly marked with safety signs. Wear personal protective equipment (PPE) when working in these areas.


1.7.5 Electrical Hazards Molding equipment draws high amperage current at high voltage. The electrical power requirements are indicated on the electrical nameplate on the electrical cabinet, and in the electrical schematics. Connect equipment to a suitable power supply as specified in the electrical schematics and in compliance with all applicable local regulations.

1.7.6 Noise Hazards Noise emissions from a single Husky Injection Molding Machine is not hazardous under normal operating conditions. However, prolonged exposure to excessive noise levels can cause hearing loss. Make sure noise levels are in compliance with all applicable local regulations. Wear hearing protection when operating equipment.

1.7.7 Gas, Vapor, and Dust Emissions Certain processed materials release harmful gas, vapors, or dust. Install an exhaust system according to local codes.

1.7.8 Slip, Trip, or Fall Hazards Do not walk, stand, climb, or sit on machine surfaces. Use an approved platform or walkway around equipment to reach areas that are not

Machine Manual

Safety Summary

1.8.2 Safety Equipment Use appropriate safety equipment when working on or near equipment. Standard safety equipment for clearing frozen resin includes: telescopic mirrors, brass hammers, and brass rods.

1.9

Ancillary Equipment Husky is only responsible for the interaction of the machine with ancillary equipment when Husky is the system integrator. If ancillary equipment is removed, proper safeguards must be installed. For information about integrating non-Husky ancillary equipment, contact a Husky Regional Service and Sales office.

1.10 Material Safety Data Sheet (MSDS) The Material Safety Data Sheet (MSDS) is a technical document which indicates the potential health effects of a hazardous product, and contains safety guidelines to protect personnel. Before handling a product, refer to the MSDS. These sheets identify hazards related to use, storage, and handling of the product, including emergency procedures. Contact the material supplier to obtain a copy of the MSDS sheet.


1.11 Materials, Parts, and Processing To prevent personal injury or damage to the equipment, make sure: 1. The equipment is only used for its intended purpose, as described in the manuals. 2. The operating temperatures do not exceed the specified permissible maximum value. 3. The maximum temperature setpoint is set below the ignition point of the material being processed. 4. Lubricants, oils, process materials, and tools used on equipment meet Husky specifications. 5. Only authentic Husky parts are used.

Table of Contents 1 Overview 1.1 1.2 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.8

1

List List the the Steps Steps in the the Inje Injecti ction on Mold Molding ing proces process s Mach Machin ine e Cyc Cycle le Oper Operat atio ion n Explain Explain How How Auxilia Auxiliary ry Comp Compone onents nts Affect Affect the Proc Process ess Identi Identify fy the Basic Basic Compon Component ents s of of the Mold Mold Identi Identify fy the Basic Basic Compon Component ents s of of the the Mach Machine ine Interp Interpret ret Machi Machine ne Nomenc Nomenclat lature ure for for Machine Machine Speci Specific ficati ations ons Contac Contactt the Corr Correct ect Sour Source ce for Trou Trouble blesho shooti oting ng Assist Assistanc ance e Test Test for for Unde Unders rsta tand ndin ing g

2 HyPET Safety 2.1 2.1 2.2 2.3 2.4 2.5 2.5 2.6 2.6 2.7 2.7

13

Oper Operat ator or-s -side ide Safe Safety ty Gate Gates s Locate Locate and and Descr Describe ibe Mach Machine ine Safe Safety ty Gates Gates-No -Non n Operat Operator or Side Side Identi Identify fy the the Purg Purge e Guard Guard and and Descri Describe be the the Purge Purge Zone Zone Ident Identify ify Devic Devices es Engin Engineer eered ed to Add Add Perso Personal nal Prot Protect ection ion Perf Perfor orm m Chec Check k of of Saf Safet ety y Dev Devic ices es Per Perform form a Lock Lockou out/ t/Ta Tago gout ut Test Test for for Unde Unders rsta tand ndin ing g

3 Using the HMI 3.1 3.2 3.3 3.3 3.4 3.4

4

25

7 Ar Areas of of th the HM HMI Manag nage User IDs Usin Using g the the Alar Alarms ms scre screen ens s Test Test for for Unde Unders rsta tand ndin ing g

5.1 5.2 5.2

6 Cl Clamp Components 6.1 6.2 6.3 6.3 6.4 6.5 6.6 6.7 6.7

8.1 8.2 8.2 8.3 8.4

39

Identi Identify fy Servic Services es Supplie Supplied d to to the the Machin Machine e Electricity Air Process Wa Water Test Test for for Unde Unders rsta tand ndin ing g

8.5 8.5 8.6 8.7 8.8 8.8

65

Identi Identify fy and and describ describe e the func functio tion n of eject ejection ion compo componen nents ts Setup etup The The Ejec jector tor Setup etup Air Eject jectio ion n Setup etup Valve alve Gate Gates s Test Test for for Unde Unders rsta tand ndin ing g

69

Identi Identify fy and and Describ Describe e the Functi Function on of Injec Injectio tion n Compon Component ents s Inje Inject ctio ion n Unit Unit Com Compo pone nent nts s Explai Explain n How Carr Carriag iage e Positi Position on is Measu Measured red and and Monit Monitore ored d Explai Explain n How Scre Screw w / Inject Injection ion Pist Piston on Posit Position ion is Meas Measure ured d and Monitored List List the the Ste Steps ps in in the the Injec Injecti tion on Cyc Cycle le Use the HMI HMI Setu Setup p Screen Screens s to Cont Control rol Injec Injectio tion n Cycle Cycle Identi Identify fy the the Valves Valves Used Used to to Contro Controll Injecti Injection on Compo Componen nents ts Test Test for for Unde Unders rsta tand ndin ing g

9 Machine Heats 9.1 9.2 9.3 9.3

49

Identi Identify fy and and Descri Describe be the the Functi Function on of Clam Clamp p Compo Componen nents ts Expla Explain in How How Clam Clamp p Positi Positions ons are are Meas Measure ured d and Moni Monitor tored ed List List the the Ste Steps ps in the the Clam Clamp p Cyc Cycle le Clam lamp Set Setu up Scr Scree eens ns Clamp Se Setup Ident Identify ify the Valves Valves Which Which Contro Controll the the Clam Clamp p Test Test for for Unde Unders rsta tand ndin ing g

7 Mold Functions 7.1 7.2 7.3 7.4 7.5 7.5

45

Expla Explain in Hydrau Hydraulic lic Oil Condit Condition ioning ing Circui Circuitt Expla Explain in the the Hydr Hydraul aulic ic Oil Oil Distr Distribu ibuti tion on

8 Injection Components

Ma Machine Services 4.1 4.2 4.3 4.4 4.5 4.5

5 Hydraulic Components

83

Identi Identify fy and and Describ Describe e the Functi Function on of Machin Machine e Heat Comp Compone onents nts Use the HMI HMI Setup Setup Screen Screens s to Contr Control ol Mach Machine ine Heats Heats Test Test for for Unde Unders rsta tand ndin ing g

© Copyright 2004, Husky Injection Molding Systems Ltd., Technical Training All rights reserved. No No part of this publication may be reproduced, reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical mechanical or otherwise, without the written permission permission of the publisher. publisher.

HyPET Operator Training

Contents

Contents

HyPET Operator Training 10 CoolPik and Tooling Plate

93

10.1 10.1 CoolP oolPik ik 10.2 10.2 CoolPi CoolPik k Coolin Cooling g Fans / C-Ax C-Axis is Motor Motor 10.3 10.3 Tool Toolin ing g Plat Plate e 10.4 10.4 CoolPi CoolPik k / Tooling Tooling Plate Plate Setup Setup Screen Screen 10.5 10.5 Diagn Diagnos osti tic c Scree Screen n 10.6 10.6 Sequ Sequen ence ce Scre Screen en 10.7 10.7 Config Configura uratio tion n Scree Screen n 10.8 10.8 HyPET HyPET Mold/To Mold/Toolin oling g Installat Installation ion 10.9 10.9 Tooling Tooling Plate Plate Remov Removal al 10.10 CoolPik Sensor Set-up / Adjustment Adjustment 10.11 Air Picker Maintenance

11 St Startup, Monitor, Shutdown 11.1 11.1 11.2 11.2 11.3 11.4 11.5 11.5 11.6 11.6

113

Fillin Filling g the Man Manif ifol old d Manual Manual Mode Mode Start Start-up -up Switching Switching to Semi Semi Automatic Automatic Mode/Robot Mode/Robot Engage Engagement/ ment/Auto Auto Monitor Monitor Machine Machine Conditions Conditions during during Operatio Operation n Shutd hutdow own n Test Test for for Unders Understan tanding ding

Glossary

135

1 Overview

Objectives  • • • • •

List List the the step steps s in the the inje injecti ction on mold molding ing proces process s Explai Explain n how auxili auxiliary ary compo componen nents ts can can affec affectt the proc process ess Identi Identify fy the the basic basic compone component nts s of the mold Identi Identify fy the the basi basic c compo componen nents ts of of the the machin machine e Interp Interpret ret machi machine ne nomenc nomenclat lature ure for for machine machine specif specificat ication ions s Conta Contact ct the corre correct ct source source for for trouble troublesho shooti oting ng assist assistanc ance e


1 Overview

1


1 Overview

2

1.1 List the Steps in the Injection Molding process Key Points: • • • • • • • • • •

Recovery (Mix and Melt the resin) Screw Transfers mass to shooting pot Close and clamp the mold Injection Hold Cool the part, same time Transfer next shot to shooting Pot Open the mold Robot Take off Plate Into Molding area Ejectors Transfer Parts to Take off plate Robot Take off Plate Out

1.2 Machine Cycle Operation Clamp (2)

Injection (1) 9

7

6 3

4

5

8 The HyPET injection molding machine consists of a two-stage injection unit (1), and a hydro-mechanical clamp unit (2). Process material pellets are fed into a heated extruder barrel (3) in the injection unit where a hydraulically driven plasticizing screw (4) rotates and turns them into a molten mass. When enough material has been plasticized, the screw transfers the mass to the shooting pot (5) and continues to plasticize more pellets. The two halves of a mold are attached to the stationary platen (6) and the moving platen (7). The stationary platen is pinned to the base (8), and the moving platen is attached to the clamp unit. Additional clamping force is then applied to keep the mold halves from separating during the injection stage. The injection piston injects a preset amount of plasticized material at very high speed into the mold cavity. This allows the molten material to fill and pack the mold cavity. Pressure is maintained until the molded part has a chance to cool. Pressure is then removed, and the plasticizing screw transfers more molten material to the shooting pot for the next injection. At the same time, clamping force is removed from the two platens, and as the two mold halves begin to separate an ejector (9) pushes the molded part off the mold.


1 Overview

3


1 Overview

4

1.3 Explain How Auxiliary Components Affect the Process Key Points: • Process water - Scaling and corrosion - Bacteria - Ambient temperature affects cooling • Resin distribution system - Introduction of contaminants • Dryers - Pellet temperature - Air temperature - Dew-point - Air volume - Residence time - Dryer efficiency • Resin supply - Material - Batch or lot number - Ship date - Weight - Melt index - Properties (color, fines, IV, Acetaldehyde, etc.)

Electrical Connections

1.4 Identify the Basic Components of the Mold

Manifold

Leader Pins

Valve Gate

Locating Ring

Sprue Bushing Core Gate

Heater Runner

Cavity


1 Overview

5


1 Overview

6

1.5 Identify the Basic Components of the Machine Key Points: • • • • • • • •

Electrical Panel Hydraulic Power Unit Clamp Extruder Motor User Interface (HMI) Product Handling Power Manifold Hopper

1.6 Interpret Machine Nomenclature for Machine Specifications Key Points:

Hylectric Series Long clamp base (option) Tonnage

MODEL MODEL

HL120PET P100/110 E120

MODEL

• • • • • • •

SERIES HYD.PRESSURE

MODEL

MAX

WEIGHT

Machine series Long clamp base option Extruder type Extruder model Screw diameter Main supply Mold heat supply

Kg

SERIAL#

THIS EQUIPMENT OR ITS USE MAY BE COVERED BY ISSUED OR PENDING PATENTS. SEE INFORMATION SCREEN AT CONTROL STATION FOR DETAILS

DATE

HUSKY INJECTION MOLDING SYSTEMS LTD. 560 QUEEN STREET SOUTH BOLTON, ONTARIO, CANADA, L7E 5S5

Two Stage Injection Unit Model P100/110 injection unit 120mm screw diameter

Main Supply

SUPPLY No.1 LOAD LARGEST MOTOR TOTAL HEAT LOAD

460 V 57 A 14 A

127 A

Mold Heat Supply

SUPPLY No.2 LOAD LARGEST MOTOR TOTAL HEAT LOAD

230 V A 74 A

74 A

MACHINE TYPE DIAGRAM Number

60 Hz 3P+GND SHORT-CIRCUIT INTERRUPTING -CAPACITY

SYSTEM

10 KA

60 Hz 3P+GND

SYSTEM

10 KA HL 120PET P100/110 E120 SERIAL Number

HUSKY INJECTION MOLDING SYSTEMS LTD. BOLTON, ONTARIO, CANADA L7E 5S5


1 Overview

7


1 Overview

8

1.7 Contact the Correct Source for Troubleshooting Assistance Key points: • • • • •

User Interface Machine documentation Husky telephone hotline Husky technical service representative Husky Technical Training courses

1.7.1 User Interface Key Points: • The user interface (HMI) is the first source of technical assistance. • Husky engineers have programmed several features into the HMI which will provide trouble-shooting assistance: - Alarms - Events - Reports - Cycle Time Breakdown - Pressure/Velocity Graphs - Valves Status - Statistical Process Control (SPC) - HMI Help


1 Overview

9


1 Overview

10 1.7.2 Machine Documentation • All Husky machines are shipped with Operation and Maintenance manuals , assembly diagrams, hydraulic schematics, and electrical schematics. This documentation may be printed or provided on a CD (in Adobe Acrobat .pdf format).

1.7.3 Husky Telephone Hotline • Husky maintains a 24-hour technical assistance hotline to provide immediate support to our customers. If you have a question about the machine operation or maintenance which cannot be answered by reading the machine manual, please call the hotline.

North America: (800) 465-4875 Europe: (352) 52 115 4300

1.7.4 Husky Technical Service Representative • You may encounter a problem which you cannot solve without expert, on-site assistance from Husky. • Husky has regional service and sales offices located around the world. • Check the listing in your machine manual for the closest location

1.7.5 Husky Technical Training Courses • The www.huskytraining.com website allows you to research and register for a wide variety of hands-on courses. You can also call our Training Coordinator at (248) 735-6339.


1 Overview

11

1 Overview


12 1.8 Test for Understanding

1. Put the steps in the injection molding process into the correct order, beginning with “Mix and Melt the resin”. ___2___

_______

_______

_______

1. Ejectors Transfer Parts to Take off Plate 2. Recovery (Mix and Melt the Resin) 3. Robot Takeoff Plate into Molding Area 4. Screw Transfers Mass to Shooting Pot

_______

_______

_______

5. Injection 6. Close and Clamp the Mold 7. Open the Mold 8. Nozzle Close / Transfer

_______

_______

_______

9. Robot Take off Plate Out 10. Hold 11. Open Machine Nozzle 12. Cool part, Transfer next shot to shooting pot

2. Locate the basic components of the Husky HyPET machine.

1. Electrical Panel 2. Extruder Motor 3. HMI 4. Hopper 5. Product Handling

3. For machine HL120PET P100/110 E120, the plunger diameter is __________ mm. 4. The Husky hotline number is _______________________________________

2 HyPET Safety

Objectives • • • • • •

Identify and understand the function of machine safety gates Identify the purge guard Describe the purge zone Identify devices on the machine designed to add personal protection Perform a check of safety devices Perform a Lockout/Tagout


2 HyPET Safety

13

2 HyPET Safety


14

2.1 Operator-side Safety Gates Key Points • Purge guard • Operator gate • Clamp access 1

2

3

7LS 352LS 333LS 8LS

1LS

(1) (2) (3)

2.2 Locate and Describe Machine Safety Gates-Non Operator Side Key Points: 4. Robot Conveyor Door 5. Robot Vacuum Door

646LS

648LS

647LS

649LS

5

4

ROBOT RESET PUSHBUTTON Press pushbutton to restart machine after opening the robot conveyor door (4).


695LS

2 HyPET Safety

15


2 HyPET Safety

16 2.3 Identify the Purge Guard and Describe the Purge Zone Key Points: • Injection is restricted unless the nozzle is within the purge guard (10mm, 0.4” overlap) • Use PPE when clearing the nozzle or sprue bushing • Limit switch S1LS monitors the purge guard and triggers an alarm when the purge guard is opened. If the switch is not made, injection is not possible

Limit Switch S1LS

2.4 Identify Devices Engineered to Add Personal Protection Key Points: Manual Dump Valve


2 HyPET Safety

• • • • •

Emergency Stop (E-stop) Pushbutton Manual Dump Valve C.E.N. Valve Automatic Dump Valve (internal - not shown) Mechanical Safety Device

17

2 HyPET Safety


18

2.5 Perform Check of Safety Devices Key Points: • • • • •

695LS 647LS

Gate

646LS

Open Gate Closed

1LS 333LS 352LS

Gate Open

Emergency Stop pushbutton Operator Gates Mechanical Safety Device Purge Guard C.E.N. valve

WARNING! Hazardous voltages, high pressure fluids, crushing or impact hazards - risk of death or serious injury. Perform Lockout/Tagout procedure in accordance with local codes. When testing the machine or troubleshooting electronics, it may not be possible to perform Lockout/Tagout. In such cases, install a danger sign at all isolation points, and rope off the area around the machine. Only qualified personnel should perform Lockout/Tagout procedure .

2.6 Perform a Lockout/Tagout Key points: • • • •

Electrical power Stored hydraulic pressure Air supply Test

1. Turn OFF Q1M Main Power and Q3M Motors Power disconnect switches on the front of the electrical cabinet. Attach a lock and a tag each switch. 2. Verify all power to the machine is off using an ammeter that has been tested on a known source. 3. Remove the cap on the gauge port marked “PP6G” in the power manifold assembly. 4. Attach a hydraulic pressure gauge to the gauge port PP6G. 5. Turn the manual dump valve counterclockwise to ensure that the accumulator is completely discharged. 6. Turn OFF the shutoff lever on the air regulator to remove the air supply to the machine. Lock out the shutoff lever using a lock and tag.

Main Power Q1M Motors Q3M


2 HyPET Safety

19

2 HyPET Safety

HyPET Operator Training 1. Complete the following chart:

Pressed when Gate OPEN

Gate Front Operator Door

=04 / S8LS

20

2.7 Test for Understanding Pressed when Gate CLOSED =04 / S7LS

Alarm Message Front Door Open

Operator Side Clamp Access Door Robot Conveyor Door Robot Vacuum Door Purge Guard C.E.N. Limit Switch C.E.N. Prox Switch Mechanical Safety Device Limit Switch Mechanical Safety Device Prox Switch 2. At the machine, find one location for each of the following tags. Explain why the tag was placed at that location: Location:__________________________________________ Reason:__________________________________________

Location: __________________________________________ Reason:

__________________________________________

Location: __________________________________________ Reason:

__________________________________________

Location: __________________________________________ Reason:

__________________________________________

Location: __________________________________________ Reason:

__________________________________________

Location: __________________________________________ Reason:

__________________________________________


2 HyPET Safety

21


2 HyPET Safety

22

Activities on this page are normally performed as a group.

3. Locate the accumulator manual dump valve. Open the manual dump valve. Turn on the pump and attempt to close the mold. Is motion possible with the manual dump valve open (circle correct answer)? YES

NO

4. List two effects on machine operation if the dump valve is left open: ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________

5. Locate the C.E.N. indicator on the Clamp Valve Status page on the HMI. Is the indicator on when the C.E.N. valve is open or closed (circle correct answer)? OPEN

CLOSED

6. List 4 locations that hot plastic can suddenly explode out of: ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________

QUESTIONS 7. Which of the following safety mechanisms are used on the injection molding machine: electrical, hydraulic, mechanical? a) electrical and hydraulic

b) electrical and mechanical

c) hydraulic and mechanical

d) electrical, hydraulic, mechanical

8. Observe the clamp valves status screen and observe the C.E.N. valve indicator. If the indicator is off (i.e. not white) it means:

a) the pump is not running b) oil is being delivered to the clamp unit c) the pump is running, all gates are closed but the switch on the C.E.N. valve has malfunctioned d) the C.E.N. valve is closed e) the C.E.N. valve is open

9. Will the moving platen close if the air supply to the machine is turned off? a) yes

b) no

10. If the electricity supply to the machine is turned off, there are times when it is safe to unbolt and remove a hydraulic valve, or loosen a hydraulic line fitting without first opening the accumulator manual dump valves. a) true

b) false


2 HyPET Safety

23


2 HyPET Safety

24

3 Using the HMI

Objectives • Identify and explain the function of the 7 areas on the HMI • Manage User IDs • Use the Alarms screens to diagnose machine issues


3 Using the HMI

25


3 Using the HMI

26 3.1

7 Areas of the HMI

Key Points • • • • • • • • •

Cycle Mode Keys Robot Home Key Robot Enable Key Manual Function Keys Message Bar Status Bar Toolbar Sidebar Functions Information Screens

3.1.1 Cycle Mode Keys Key Points • • • • • • • •

Cycle Start Auto Semi Manual Robot Enable Robot Home Pump Motor On Pump Motor Off

3.1.2 Manual Function Keys Key Points


3 Using the HMI

• • • •

Mold Open/Close Unclamp/Clamp Ejector Auto/Backward Ejector Forward

• • •

Inject Screw Rotate Carriage Forward/Back

• •

Mold Cooling Valve Gate Open

27

3 Using the HMI


28 3.1.3 Message Bar

11:13:24 AM - Front Gate : Gate Open Active

• • •

Inactive Red

Gray

Yellow

Gray

Key Points Most recent Alarm message Machine Stop Alarm Active/Inactive Machine Warning Alarm Active/Inactive

3.1.4 Status Bar °C

°F

60 - 140 58 - 136

Pump off

Key Points

Pump off after 5 minutes

• • • •

No Auto Cycle after 30 minutes

55 - 130 High Oil Temperature alarm

53 - 127 Normal operating temperature

47 - 116 Low Oil Temperature alarm

45 - 113 5

- 41

Oil temperature too low machine in oil warming Pump off

Cycle Mode Indicator Machine Cycle Time Oil Temperature Current User

3.1.5 Toolbar Key Points • • • • • • • • •

Normal

Dry Cycle

Screen Capture Administration Utility Calibration Machine Function Mode Alarm horn On/Off HMI Configuration User Log On/Off Datakey (HPN 2280038) Help (not available)

Auto Purge

Mold Set

Unload Pumps

Screw Change


3 Using the HMI

29


3 Using the HMI

30 3.1.5.1 HMI Configuration Key Points • • • • •

Password Units Language Shifts Others

3.1.6 Sidebar Functions Display pre-programmed function groups

Key Points Function Group / Status

• •

Area of machine

Both Sidebars (left and right) have identical functions Sidebars can show: - Process values - Manual operation functions - Pre-programmed function groups - User-programmed function groups (2 user function groups available) - Programming the function groups is accessed through User Group #2

Process or affected component

Process Value

User Groups


3 Using the HMI

31


3 Using the HMI

arm - A arms - Events History M - Reports Selection M - Report View M - Log Transfer P Overview - Machine Specifications M - CycleTime Breakdown M - Graph M Setup - Production Setup P - Mold Setup P - Mold Installation P Clamp - Overview O - Setup P - Graph M - Valves Status M Options - Ejector/Core P - Ejector Setup P - Air P - Valve Gates M Extruder - Overview O - Injection P - Injection Graph M - Recovery P - Recovery Graph M - Valves Status M Heats - Barrel P - Mold P Robot - Production M - Program Manager P - Sequence Editor P - Diagnostic M - Settings M SPC - Summary M - Details P - History M - Group M - Setup P

32

3.1.7Information Screens Key Points • • •

M -Monitor-level

screens (no setpoints which can affect process) O -Operator-level screens (restricted variation in setpoints) P -Process-level screens (full process control)

3.2 Manage User IDs

Key Points • • • •


3 Using the HMI

Users Groups Rights Others

33

3 Using the HMI


34

Table 1: User Rights Summary View View Operator screens Adjust sliders Change Operator setpoints Change Process setpoints Calibrate machine Switch languages and units Manage machine users and rights Recall mold setup parameters Change machine Change date and time formats Set shifts Install molds

Operator

Processor

Maintenance

Administrator

3.3 Using the Alarms screens

Key Points • • • • •

Alarms Events Reports Select Reports View Log Transfer

3.3.1Alarms •

Alarms are shown as active or inactive

3.3.2Events • • • •


3 Using the HMI

Event Count = number of events displayed in current filtered list (20,000 maximum) First column shows an appropriate icon related to the type of event Click on the title at the top of each column to sort results by that column is designed to make it easier to analyze Events History

35


3 Using the HMI

36

3.3.3Reports Select • •

Left side of screen manages on-demand reports Right side of screen manages on-schedule reports

3.3.4Reports View •

Summary at end of report lists types of events and frequency

3.3.5Log Transfer • • • •

•

Event Log - allows retention of Event History Data Log - all SPC variables which are tracked by the machine Data Log (SPC) - SPC variables which have been selected for monitoring “Transfer” copies data to a floppy disk in a .csv (comma-separated variable) file which can be read by a spreadsheet program. When a log is full, oldest entries are dropped as new entries are added

3.4 Test for Understanding 1. Use the letters to identify the areas on the HMI A B C D E F G H

-

Toolbar Manual Function Keys Message Bar Information Screens Sidebar Functions Status Bar Cycle Mode Keys Sidebar Functions

2. Create the following user on the machine: Name: morning crew Password: husky Access Level: Process Login using the new user. Increase the tonnage by 1T. Change the tonnage back to its original value. Logoff. 3. Use the Event History screen to determine which setpoint has been changed most often in the last 3 weeks - __________ 4. How many times has that setpoint been changed? ______________ 5. As a class, discuss the setpoint changes Are the number of changes reasonable? Do any of the changes point to a maintenance or process issue? What are some examples of situations where multiple setpoint changes might be masking a problem?


3 Using the HMI

37


3 Using the HMI

38

4 Machine Services

Objectives • Identify the services supplied to the machine • Describe the function of each machine service • Locate the control and monitoring devices for each service


4 Machine Services

39


4 Machine Services

40 4.1

Identify Services Supplied to the Machine

Key Points • • • • • •

Electricity (Lockout/Tagout location) Air (Lockout/Tagout location) Robot air (Lockout/Tagout location) Becker vacuum pump air (Lockout/Tagout location) Process Water Mold Cooling Water - Mold cooling water supply specifications are dependent upon the mold. Refer to the mold manual for details.

4.2

Electricity

Key Points • •

•


4 Machine Services

Lockout Process or machine monitor devices - Limit/Proximity Switches - Temposonic Rods - Pressure Transducers - Thermocouples Machine control devices - Pump Motor - Variable Displacement Pumps - Valves - Screw Motor - Barrel Heats - Mold Heat

41


4 Machine Services

42 4.3

Supply (70-150psi) Auxiliary Functions (Robot)

Air

Key Points • • • • • • •

Regulator / Lockout Filter Pressure Switch Water Saver valve Hopper Open valve Air Ejection or Valve Gates (optional) Mechanical Safety Device

4.4

Process Water

Key Points • • • • • • • • •


4 Machine Services

Feed Throat Hydraulic Oil Robot Extruder Motor Pump Motor Electrical Panel / Servo Drive cooling (large systems) Required Temperature/Flow/Pressure Quality Adverse effects from improper process water supply

43

4 Machine Services


1. Which of the following is NOT a service supplied to the machine? A C -

Hydraulic Oil Process Water

B D -

Electricity Chilled Water

2. When the machine has 3 main electrical disconnect switches, what do they control? (Circle 2 answers) A C E -

Mold heating Clamp functions Machine functions

B D F -

Machine heating Injection functions Pump Functions

B D -

70psi 150psi

3. What is the minimum air pressure required? A C -

0psi 90psi

4. Circle all of the following qualities which are important to cooling water. A C E -

Inlet pressure Inlet temperature Flow

B D F -

Pressure drop Outlet temperature Amount of scale

Note: The next activities should be performed as a group at the machine . 5. Check the operation of the air pressure switch on the machine (full class activity). 6. Check for water in the air filter. Bleed if necessary. 7. Identify all devices which require cooling water. 8. At this machine, how can the operator determine that water pressure drop and flow through the heat exchanger is adequate. A C -

Not the responsibility of our operators Pressure gauges

B D -

Flow switch Not possible

44 4.5

Test for Understanding


Objectives • Explain the hydraulic oil conditioning circuit • Explain hydraulic oil distribution



45



46

5.1

Explain Hydraulic Oil Conditioning Circuit

Key Points • • • • • •

Hydraulic Oil Oil Tank Filter Pump Oil Filter Water Saver Valve Heat Exchanger

5.2

Explain the Hydraulic Oil Distribution

Key Points • Pumps • Accumulator • C.E.N. - closes when an operator door opens to block all oil used for mold stroke motion • Clamp - Clamp Piston - Stroke - Ejector/Cores • Injection - Shutoff Nozzle - Injection Piston - Carriage

C.E.N

Carriage



47



48

6 Clamp Components

Objectives • • • • •

Identify and describe the function of clamp components Explain how clamp positions are measured and monitored List the steps in the clamp cycle Use the HMI setup screens to control the clamp cycle Identify the valves which control the clamp


6 Clamp Components

49


6 Clamp Components

50 6.1 Identify and Describe the Function of Clamp Components Key Points • • • • • • • •

Mold Cavity and Core Platens (stationary and moving) Mechanical Ejection Tiebars Clamp Column Clamp Lock Clamp Piston and Clamp Cylinder Linear Bearing

6.1.1 Clamp Lock

1

Key Points • (1) Mold closes • Stepless shutheight adjustment is achieved through a combination of the clamp piston stroke and the column teeth pitch • (2) Clamp piston rotates 30 ° to lock on the

column

4

2

• (3) High pressure oil is supplied to the cap end of the clamp piston to provide clamp force • Oil is supplied to the rod end of the clamp piston to re-position it to home, and to provide up to 10% of clamp tonnage for mold break • (4) The clamp piston rotates 30 ° to unlock

the column • (1) Mold opens and clamp piston resets

3


6 Clamp Components

51

6 Clamp Components


530.8

52 6.2 Explain How Clamp Positions are Measured and Monitored

mm

Key Points • • • •

300

Clamp Piston Position Shutheight Position

600

to

mm

10.0 mm

Stroke Position

0.0 mm

203.0 mm

Stroke Pressure

0.0 psi

Magnetic field

Excitation field

Twisting pulse Protective tube

Waveguide Position magnet

Sensor head

Shutheight Mold Stroke Clamp Piston Temposonic Rod - Excitation field forms along entire waveguide for 1-3 microseconds - Interaction of magnet field and excitation field causes a twisting strain pulse to form on the waveguide. The pulse travels along the waveguide at a known speed. - Strain gauges in the sensor head detect the twisting pulse when it reaches the end of the rod - The elapsed time between the formation of the waveguide and the time that the pulse reaches the sensor head indicates position

6.3 List the Steps in the Clamp Cycle

Start

I n j e c ( no n t t io i n D U n i t r y C y cl e )


6 Clamp Components

53


6 Clamp Components

54 6.3.1 Mold Close Key Points • Begins when Cycle Start is pressed (first cycle) or when Mold Open timer is complete (subsequent Auto Cycle) • Center Actuator (piston/cylinder) • High Speed, Low Force • Speed Controlled • Multiple Stages (if necessary) • Pressure controlled at end for Part Interference 1

2

2000 400 340.0 170.0

1

mm/s 0.0 mm

2

6.3.2 Clamp Up Key Points • • • • •

Tonnage

0.0

Mold Break Clamp Piston Position Shutheight Position


0

Begins when Stroke Position = 0mm Clamp Lock High Force Short Stroke Tonnage as required by mold design

212 T 3.6 mm 10.0 mm 203.0 mm

6 Clamp Components

55


6 Clamp Components

56 6.3.3 Wait for Hold Complete Key Points • Bypassed in Dry Cycle • Injection occurs in two stages - Inject (speed/ position-controlled) then Hold (pressure/timecontrolled)

6.3.4 Cooling Time Key Points

Cooling Time

0.00 1.00 s

• Begins when last hold time is complete • The time while the part is on the core before ejection is also cooling time) • Mold cooling water temperature and flow variations affect cooling time • Part quality is affected by cooling

6.3.5 Unclamp and Mold Break Key Points • Begins when cooling time is complete • Decompress the clamp piston • Re-position the clamp piston for teeth clearance • Clamp piston continues to retract for mold break • Clamp Lock off • Re-position the clamp piston to home

6.3.6 Mold Open Key Points • Begins when Clamp Lock Off proximity switch is made • Center Actuator (piston/cylinder) • Speed Controlled • Multiple Stages (if necessary)


6 Clamp Components

57


6 Clamp Components

58 6.4 Clamp Setup Screens Key Points: • Overview • Setup

6.4.1 Overview Key Points • • • • • • •

Close Safety Decel Part Interference Tonnage Cooling Time Mold Break Open Safety Decel Mold Open Time

6.5 Clamp Setup Key Points: • Low Pressure Start • Mold Break

6.5.1 Mold Close Theory Key Points Mold Close Decel

5000 mm/s2

Mold Close Final Speed

Low Pressure

Low Pressure Start Mold Protection Time

20 mm/s

1300 psi

5.0 mm 1.00 s Part Interference

0.6 mm

Speed Pressure


6 Clamp Components

• Mold Close Decel - set a predicted value so the clamp can calculate stopping distance (higher numbers mean the moving platen can stop quicker) - if the value is too large, the mold halves may slam together - a low value may increase cycle time - larger molds with more inertia may require a lower Close Safety Deceleration • Mold Close Final Speed - moving platen speed when the mold halves come together • Low Pressure - set a value which allows the moving platen to stall if it encounters interference (instead of crushing an obstruction into the mold) • Low Pressure Start - pressure in the stroke cylinder is restricted to the Low Pressure value at this point - if the moving platen encounters an obstruction after this point, pressure will hold at Low Pressure, stalling the movement of the moving platen • Mold Protection Time - after the Low Pressure Start position is reached, the moving platen has a set amount of time to close, otherwise the Part Interference alarm is triggered • Part Interference - any obstruction smaller than this value will not interfere with the cycle - mold closing finishes at required pressures

59

6 Clamp Components


60 6.5.2 Mold Open Theory Key Points

Mold Open Deceleration

4200 mm/s2

Mold Break Mold Open Final Speed

Speed

0.0 mm 15 mm/s

• Mold Open Deceleration - set a predicted value so the clamp can calculate stopping distance (higher numbers mean the moving platen can stop quicker) - if the value is too large, the mold stroke may not be able to stop at the Mold Open setpoint (the mold may slam into stroke limiters) - a low value may increase cycle time - larger molds with more inertia may require a lower Open Safety Deceleration • Mold Break - use the clamp piston to open the mold (available force is approximately 10% of full tonnage) • Mold Open Final Speed - moving platen speed when the the mold open setpoint is reached

6.5.3 Mold Close Profile Key Points • • • • • • • • • • • •


6 Clamp Components

Low Pressure Start Low Pressure Mold Close/Open Deceleration Mold Close/Open Final Speed Part Interference Tonnage Cooloing Time Mold Break Mold Open Time Mold Stroke Position Mold Stroke Pressure Shuheight Position

61


6 Clamp Components

62 6.6 Identify the Valves Which Control the Clamp Key Points • Mold Stroke • Ejector • Clamp Lock - holds oil on the clamp side of the clamp piston when in auto to help maintain position - holds tonnage on the clamp when clamped in manual • Clamp

6.7 Test for Understanding 1. Identify the components: A F -

Stationary Platen Clamp Column

B G -

Clamp Lock Tiebars

C H -

Moving Platen Mold Core

D J -

Clamp Piston Ejector rod

E K -

Clamp Cylinder Linear Bearing

A


6 Clamp Components

63

6 Clamp Components


64

2. Select the correct order of buttons to manually cycle the clamp:

1 3. If a higher mold is installed in the machine (requiring greater shutheight) the maximum mold open position will A -

increase

B -

decrease

C -

remain the same

4. On the machine used for this class, how many stages are used for Mold Close? Why?

5. If a heavier mold is installed in the machine, the operator will probably have to: A -

increase Safety Deceleration

B -

decrease Safety Deceleration

C -

make no changes to Safety Deceleration

6. Mold Open begins: A -

when Hold is complete

B -

when the Clamp Lock Off prox is made C -

when the Cooling Timer is complete

7 Mold Functions

Objectives • • • • •

Identify and describe the function of ejection components Setup the Ejector Setup Mold Functions Setup Air Ejection Setup Valve Gates


7 Mold Functions

65


7 Mold Functions

66

7.1 Identify and describe the function of ejection components Key Points • • • • •

Cylinder Piston Rods Plate Temposonic Rod

7.2 Setup The Ejector Key Points • Speed/Pressure/Position Control • Number of Strokes • Forward Dwell

7.3 Setup Air Ejection Key Points: • Function (moving/stationary platen) • Start Trigger - Mold Position - End of Cooling - Start of Cooling • Delay Time • Blow Time • Valve Status •

7.4 Setup Valve Gates Key Points: • • • • • • •


7 Mold Functions

Open Trigger Mold Open End Mold Close Start Open Delay Neutral During Close Delay Valve Status

67

7 Mold Functions


68 7.5 Test for Understanding

1. On the Ejector Setup screen, if the Number of Strokes is set to 3, the Forward Dwell time applies each time the ejector move foward. A - True

B - False

2. To turn on Air Ejection before the mold has started to open, select the trigger: A - Mold Position

B - End of Cooling

C - Start of Cooling

D - It is not possible

3. When using Valve Gates, the following conditions could cause drool at the mold gate: A - Open Delay too long

B - Open Delay too short

C - Close Delay too long

D - Close Delay too short

E - A or C

F - B or D

G - B or C

H - Valve Gate operation does not affect drool


Objectives • • • • • •

Identify and describe the function of injection components Explain how the carriage position is measured and monitored Explain how the screw / injection piston position is measured and monitored List the steps in the injection cycle Use the HMI setup screens to control the injection cycle Identify the valves used to control injection components



69



70 8.1 Identify and Describe the Function of Injection Components Key Points: 1. Nozzle 2. Shooting Pot 3. Barrel 4. Plasticizing Screw 5. Feed Throat 6. Hopper Shutoff 7. Injection Piston 8. Transfer Cylinder 9. Gear Box 10. Extruder Motor

8.2 Injection Unit Components

Extruder Motor


Injection Manifold


Barrel Heats (Profibus)

71



Forward

72 8.3 Explain How Carriage Position is Measured and Monitored Key Points:

Contacting Sprue Bushing

Too Far Forward

Carriage Position Forward Too Far Forward

41.2

mm

43.0

mm

39.0

mm

• • • • • • •

Carriage Forward Position Nozzle Contacting Sprue Bushing Carriage Too Far Forward Position Carriage Position Display Carriage Piston Temposonic Rod Purge Area

8.4 Explain How Screw / Injection Piston Position is Measured and Monitored Key Points: • • • •

Injection Pos.


Temposonic Rod Carriage magnet Injection magnet Position display

0.4 mm


73



74 8.5 List the Steps in the Injection Cycle

Recovery (RPM and Back Pressure controlled) note 1: Nozzle will be open if Post-Pullback selected Mold Closing - Carriage Forward, Nozzle Open

Pullback (decompress mold and manifold) note 2: Will take place after recovery if Post-Pullback selected

Wait for Mold Clamped

Hold (pressure controlled) Injection (speed controlled)

8.5.1 Recovery Key Points • • • • • •

Nozzle closed RPM Back Pressure Shot Size Mixing and Compression Process Heat

1

50 rpm 0.0

53.0 mm 45 psi



75



76 8.5.2 Injection Key Points • Shutoff Nozzle Open • Check Valve Closed • Speed/Position Controlled

2

1

37.0

113.0 mm/s

21.0

53.0 mm

8.5.3 Hold Key Points • Shutoff Nozzle Open • Check Valve Closed • Pressure/Time Controlled

2

2600 0.5

1

780 psi 1.5 s

8.6 Use the HMI Setup Screens to Control Injection Cycle

Key Points • Overview • Injection • Recovery

8.6.1 Overview Key Points • • • • • • •



Shot Size Fill Speed Transition Hold Time, Hold Pressure Pre- and Post-Pullback Distance Screw Speed Back Pressure

77



78 8.6.2 Injection Profile Key Points • Screen design follows screw orientation (left to right motion) • Injection Profile (graph) • Injection Profile (fields) • Hold Profile (graph) • Hold Profile (fields)

8.6.3 Injection Control • Transition - Time - Position - Hydraulic Pressure - Cavity Pressure - Pressure Enable Position • Cushion • Cushion Control • Cooling Time • Maximum Fill Pressure • Excess Injection Time • Feedback - Injection Position - Fill Speed - Fill Pressure - Shot Size

8.6.4 Recovery Profile Key Points • • • • • • • • • • • •

•



Screw RPM Back Pressure Profile Graph Profile Fields Pre-Pullback (decompress mold and manifold before Recovery) Post-Pullback (use Back Pressure during Recovery as additional Hold time/pressure) Hopper Open Screw Rotation Delay (after Pullback) Auto Purge Cycles Nozzle Shutoff Enable (maintain Nozzle Open) Nozzle Open Delay (after the start of Mold Close) Carriage Forward - At Mold Close - At 10% Tonnage - At Tonnage - Maintain Sprue Break (Sprue Break will be automatically 0mm with Maintain Carriage Forward)

79



80 8.7

Identify the Valves Used to Control Injection Components

Key Points: • Injection servo valve • Carriage Forward/Back digital valves • Nozzle Shutoff digital valve

8.8

Test for Understanding

1. Identify the following components

A - Feed Throat F - Plasticizing Screw

B - Shooting Pot G - Injection Piston

C - Hopper Shutoff H - Transfer cylinder

D - Barrel I - Extruder Motor

E - Gear Box J - Nozzle

2. The carriage position when it is contacting the sprue bushing on a particular machine is 36.2 mm. Fill in the fields shown with appropriate values.


Carriage Position

mm

Forward

mm

Too Far Forward

mm


81



3. Put the parts of the Injection Cycle in the correct order: ___ Pullback

1 Recovery

___ Hold

___ Injection

___ Nozzle Open

4. During Hold, plastic: A - continues to enter the mold as the plastic shrinks B - decompresses the mold by flowing back through the sprue bushing

5. For the mold shown, the injection speed when the plastic is flowing through section 1 should be: A - faster than section 2

B - slower than section 2

C - the same as section 2

6. Changing the transition point so that it occurs earlier in the cycle will tend to: A - Increase part weight

B - Decrease part weight

C - Have no effect on part weight

7. In order to maintain the Shutoff Nozzle open: A - “Check” Nozzle Shutoff Enable

B - “Uncheck” Nozzle Shutoff Enable

82

9 Machine Heats

Objectives • Identify Identify and and describ describe e the function function of of Machine Machine Heat component components s • Identi Identify fy and and loca locate te all all Mach Machine ine Heat Heat zone zones s • Use the the HMI HMI setup setup scree screens ns to cont control rol the the Machin Machine e Heats Heats


9 Machine Heats

83

9 Machine Heats


84 9.1 Identif Identify y and and Descri Describe be the the FuncFunction of Machine Heat Components Key Points: • Bar Barrel rel • Heat Heater er Band Band • Thermo Thermocou coupl ple e

Thick heat-insulating backing Thin, heat-conducting inner layer Stainless-steel sheath Coiled heater element Electrically-insulating, heat-conducting mineral layer around heater element

9.2 Use the HMI Setup Setup Scre Screens ens to Control Machine Heats Key Points: • • • • •

Barrel Barrel Setup Setup Scree Screen n Mold Mold Setup Setup Scree Screen n Nozzle Nozzle Tips Tips Screen Screen Machine Machine Heats Heats Setup Setup Screen Screen Heats Heats Schedul Scheduler er Popup Popup Screen Screen

9.2.1 9.2.1 Barrel Barrel Setup Setup Scree Screen n Key Points: • Machine Machine Heats Heats Enabl Enable e • Resin Resin Tempe Temperatu rature re


9 Machine Heats

85


9 Machine Heats

86 9.2.2 Mold Setup Screen Key Points: • Mold Heat Zones • Mold Heats Enable • Global Control

9.2.3 Nozzle Tips Screen Key Points: • Mold Heats Enable


9 Machine Heats

87


9 Machine Heats

88 9.2.4 Heats Setup Screen Key Points: • Machine Heats - Machine Heats Enable - Soft Start - Self Tune - Use Heat Scheduler - Soak Time - Standby - M/C Idle Standby Delay • Mold Heats - Mold Heats Enable - Soft Start - Self Tune - Use Heats Scheduler - Soak Time - Standby - M/C Idle Standby Delay • Nozzle Tip Heats - Nozzle Heats Enable - Soak Time

Global alarms

click

9.2.5 Setup Machine Heats Key Points: • High Alarm (absolute) or High Deviation (calculated range) triggers Heat Contactor off • Low Alarm (absolute) or Low Deviation (calculated range) inhibits extruder functions • Soft Start is used to reduce heater band failure • At the conclusion of Soft Start, normal heats control is restored • Auto Control allows the controller to attempt to maintain the setpoint • Manual Control (where available) allows the operator to set the Heat On % • Auto Tune allows the controller to re-calculate Heat control settings to reduce hunting around setpoint

High Deviation Setpoint (target) Low Deviation

c k c l i

Global (all zones) change to displayed settings c l i c k

Min/Max Value 550 0

Thermometer Display Range


9 Machine Heats

89

9 Machine Heats


Mon

Tue

Wed

Thu

Fri

Sat

Sun

90 9.2.6 Heats Scheduler Popup Screen

Barrel

Key Points:

Mold

• • • •

Use

ON

OFF

Setting 1

Monday

6

0

Monday

20

0

Setting 2

Tuesday

6

0

Tuesday

20

0

Setting 3

Wednesday

6

0

Wednesday

20

0

Setting 4

Thursday

6

0

Thursday

20

0

Setting 5

Friday

6

0

Friday

20

0

Setting 6

Saturday

7

30

Saturday

4

30

Setting 7

Sunday

7

30

Sunday

4

30

“Week-at-a-Glance” Current date/time indicator 7 programmable zones Program the machine heats based on production shifts and process requirements

9.3 Test for Understanding

6 9

8 2 1

5

7

3

10

4

1. In order to open the Soft Start Control settings window, select item ________

2. If the heat zones are not able to maintain precise temperatures, try selecting item ________


9 Machine Heats

91


9 Machine Heats

92

3. To limit the minimum temperature for extruder operation for a specific zone, select item ________

4. The main heat contactor will turn off if the High Alarm is triggered.

True

False

5. The main heat contactor will turn off if the high deviation for a specific zone is triggered.

True

False

6. To set the Soft Start Soak Time, select item ________

7. The 15% value for Extr. 1 means: a) the temperature is within 15% of the setpoint

b) the heater is on at 15% of rated amps

c) the heater is on for 0.15 seconds, off for 0.85 seconds

d) the heater is manually set to cycle at 15%

8. To change the visible range of the thermometer, select item ________

9. When Standby is selected, all barrel zones will be reduced a) by 175 oF

10. If Extr.1 is set too low, Extr. 2 may run too high

b) to 175oF

True

False

10 CoolPik and Tooling Plate

Objectives • • • • • • • •

Identify and understand CoolPik operation Identify and understand Tooling Plate operation HyPET Mold/Tooling Installation Tooling Plate Removal Interpret Setup Screen HyPET CoolPik Sensor Set-up and Adjustment Pre-stretching the Air Pickers Installation of Air Pickers


CoolPik and Tooling Plate

93



94

10.1 CoolPik Key Points:

(1)

• CoolPik removes preforms from tooling plateand transfers preforms to conveyor. • CoolPik Bladder, “air picker” (1) • CoolPik Rotation - Vertical - Horizontal • CoolPik Rotation Speeds - Auto/Manual - Jog - Mold Position for CoolPik Safe to Rotate • Fiber Optic Part Detection (2)

Fiber-optic Connections

(2)

(1)

10.2 CoolPik Cooling Fans / C-Axis Motor Key Points:

(2)

• CoolPik in drop position over fiber-optic cable (1) • Cooling fans (2) • C-Axis Motor (3)

(3)



95



96

10.3 Tooling Plate Key Points

(1)

• Tooling Plate In/Out Speeds - Auto/Manual - Jog • Machine Protection - Tooling plate photo-eyes (1) - Mold Position for Tooling Plate Safe to Enter - Ejector Position for Tooling Plate Safe to Exit

Tooling plate photo-eye reflectors

10.4 CoolPik / Tooling Plate Setup Screen Key Points • Tooling Plate In/Out - Wait Position • Stage Enabled - In Position - Out Position - Occupied - Vacuum - Air Blow - In - Out • CoolPik Bladder - Part Drop Duration • CoolPik Rotation - Vertical - Horizontal • CoolPik Rotation Speeds - Auto/Manual - Jog • Tooling Plate In/Out Speeds - Auto/Manual - Jog • Machine Protection - Mold Position for Tooling Plate Safe to Enter - Mold Position for CoolPik Safe to Rotate - Ejector Position for Tooling Plate Safe to Exit



97



98

10.5 Diagnostic Screen Key Points • Machine Status - Mold Open - Mold Closed - Ejector Retracted - Ejector Forward - No Part Available - Ready for Part Pick • Tooling Plate - Cooling - Vacuum Relief - Tooling Plate In/Out • CoolPik - CoolPik Rotation • Product Handling Status - Permit Mold Close - Permit Clamp Motion - Permit Ejector Forward - Permit Ejector Back • Conveyor - Forward - Reverse • Photo Eyes Clear - Tooling Plate - CoolPik - Mold

10.6 Sequence Screen Key Points • Product Handling Sequence - Mold Cooling - CoolPik Bladder Inflated - Vacuum Off, Air Blow and Mold Open - Check Tooling Plate Photo Eyes Clear - Vacuum ON - Mold Open at Tooling Plate Safe to Enter - Tooling Plate to in stage Position - Mold Open at CoolPik Safe to Rotate - CoolPik to Horizontal - Ejector A Forward - Ejector Retracted - Tooling Plate to Out Stage Position - Check CoolPik Photo Eyes Blocked - CoolPik Bladder Deflated - Check CoolPik Photo Eyes Clear - CoolPik to Vertical - Permit Mold Close



99



100

10.7 Configuration Screen Key Points • Part Drop Signal • Tooling plate photoeyes and CoolPik photoeyes enable • Mold photoeyes enable • Mold sensor enable

10.8 HyPET Mold/Tooling Installation 1. Place the machine in Mold Set mode. 2. Install the mold. 3. Open the shutheight enough to work inside (approximately). Some molds may require installation of the core side and the cavity side in separate operations. 4. Perform machine clamp calibration (must be done before the CoolPik calibration). 5. Calibrate CoolPik axis without CoolPik plate. Once the calibration is complete the axis will rotate to the setpoint of 90 degrees, which will be approximately vertical orientation. 6. Calibrate tooling plate axis without the tooling plate installed. 7. Move the tooling plate carriage to maximum “in-mold” nominal position.

WARNING! Complete the Lockout/Tagout procedure in accordance with applicable local codes before performing maintenance activities. Failure to do so can result in injury or death.

8. Lockout / Tagout the machine. 9. Open the gates, move tooling plate carriage by hand and install alignment pin through the tooling plate carriage casting into the beam (this locates the stage 1 “IN” position for the system for any mold). 10.Save this exact position in the software/program. Stage 2 and 3 positions are calculated from the stage 1 position. 11. Remove the alignment pin and close the gates. 12.Remove Lockout / Tagout. Removing Lockout/Tagout, page 1-16. 13. Move the tooling plate axis out of molding area until the tooling plate mounting face on the carriage is adjacent from the outer vertical edge of the plenum (the carriage will be approximately 200mm from the outboard bumpers). 14. Close the mold/moving platen until the shutheight is approximately 700mm. NOTE: This step must be performed without the tooling plate attached to the carriage, or CoolPik plate attached to the plenum casting. 15.Lockout / Tagout the machine.



101



102

16.Measure the horizontal distance from the tooling plate mounting surface of the carriage to the CoolPik plate mounting surface of the plenum casting at the locations of the two dowels. Measure dimensions A and B.

17. Remove Lockout / Tagout. 18. If the difference between dimensions A and B is larger than 4mm, return to the HMI and rotate the plenum assembly in the appropriate direction until the difference in the two dimensions is less than 4mm. Repeat until successful. 19. Lockout / Tagout the machine. 20. Open the mold.

WARNING! Inadequate lifting equipment can fail and cause injury or death. Make sure the lifting eye bolts, chains/slings and lifting device are rated for the load and in safe operating condition.

WARNING! Crushing hazard - risk of death or serious injury. Do not work under suspended loads. To prevent injury, install safety blocks. 21. Use a crane of sufficient capacity to lift and lower the tooling plate/CoolPik plate assembly into the machine. NOTE: The following procedures on mold installation require the use of a crane, make sure the li fting eyebolt, lifting chain and crane can support the weight of the plate(s). NOTE: In some cases, it could be necessary to remove the dehumidification tent/top guard or other components that might interfere with the crane or mold being hoisted. 22.Position the tooling plate/CoolPik plate assembly (dowel/pinned together) and install entire assembly onto the z-carriage. Torque all mounting screws to the required specification. Refer to Recommended Torques. 23. Install the coolant hose assembly to the manifold. Torque all mounting screws to the required specification. Refer to Recommended Torques. 24.Remove the lifting chain and crane. 25.Move/jog the tooling plate carriage to the approximate outer position where the 14 mounting holes in the CoolPik plate are aligned with the plenum casting. More adjustments can be made later when the plenum is brought closer to the tooling plate CoolPik plate assembly. 26.Remove Lockout / Tagout. 27.Check that the machine is in Mold Set mode. 28.Close the mold slowly until there is a 15mm gap between the mold parting lines. REMINDER: The CoolPik plate is still doweled/attached to the tooling plate.



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29.Check that the CoolPik plate holes are aligned with the plenum casting. If adjustments are required, the entire tooling plate carriage with attached tooling plate/CoolPik plate assembly can be moved by hand for adjustments. 30.The HMI software set-up procedure will then request the operator to release the C-Axis/ CoolPik servo brake. 31. The HMI software set-up procedure will then allow the operator to close the mold the remaining 15mm, while the c-axis/CoolPik servo brake is still released. This will re-align the plenum casting to some degree. WARNING! Complete the Lockout/Tagout procedure in accordance with applicable local codes before performing maintenance activities. Failure to do so can result in injury or death. 32.Lockout / Tagout the machine. 33.Open non-operator’s side conveyor bi-fold door. 34.Loosen the 4 mounting screws on the back of the tooling plate to the spacer blocks by roughly 5mm to allow the tooling plate and CoolPik plate to separate (by 5mm). 35.Install the M10 mounting screws through CoolPik plate to the plenum casting along the non-operator’s vertical edge. Since the servo brake is released, the plenum will be able to rotate to an angle which is perfectly parallel to the tooling plate. As these M10 screws are tightened, the CoolPik plate will slide 2mm along the 4x spacer block screws towards the plenum casting. 36. Torque CoolPik mounting screws to required specifications. Refer to Recommended Torques. 37.Remove completely the 4 mounting screws securing the Coolpik plate to the tooling plate. 38.Install the air connection to the side of the CoolPik plate. (1) 39.Save this CoolPik servo angle into the software/program. This is the exact repeatable angular position for every cycle. The calibration is only accurate to within 2 degrees. This procedure improve the angular accuracy to less than 0.1 degrees. 40.Close the gate. 41.Remove Lockout / Tagout. 42.Reactivate the C-axis servo brake according to the HMI software set-up procedure. 43.Open the mold/moving platen to allow access to the CoolPik plate.

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44.Lockout / Tagout the machine. 45.Open non-operator’s side conveyor bi-fold door, insert and tighten the remaining M10 bolts securing the CoolPik plate to the plenum casting. (i.e. the upper and lower horizontal and the inner vertical bolts of the CoolPik plate). Torque CoolPik mounting screws to required specifications. Refer to Recommended Torques. We now have all 3 critical locations: • • •

IN position for stage 1 (same for all molds), for transfer of preforms from mold to EOAT (tolerance +/- 0.1mm) OUT position for stage 1 (varies according to the mold & cavitation), for transfer from the tooling plate to the CoolPik (tolerance +/0.2mm) ANGLE for optimal part transfer from tooling plate to CoolPik (tolerance +/-0.1 degrees to achieve locational tolerance of +/- 0.2mm)

NOTE: ANGLE for preform drop off from CoolPik is not important except possibly with singulator applications. A 90 degree rotation is usually prescribed. 46.Remove Lockout / Tagout. 47.Move the tooling plate into the molding area. 48.Insert the tooling plate alignment pin into the cavity plate locating hole. This check can be performed in all 3 positions, if the pin fails to locate in position 1, repeat in positions 2 or 3. NOTE: If the pin fails to align with the cavity plate in any position, contact your nearest Husky Service Center.



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WARNING! Complete the Lockout/Tagout procedure in accordance with applicable local codes before performing maintenance activities. Failure to do so can result in injury or death. 1. Lockout / Tagout the machine.

WARNING! Inadequate lifting equipment can fail and cause injury or death. Make sure the lifting eye bolts, chains/slings and lifting device are rated for the load and in safe operating condition.

WARNING! Crushing hazard - risk of death or serious injury. Do not work under suspended loads. To prevent injury, install safety blocks.

NOTE: The following procedures on mold installation require the use of a crane, make sure the li fting eyebolt, lifting chain and crane can support the weight of the plate. NOTE: In some cases, it could be necessary to remove the dehumidification tent/top guard or other components that might interfere with the crane or mold being hoisted. 2. Use a crane of sufficient capacity to remove the tooling plate from the machine. 3. Shutoff the coolant supply line. 4. Remove the coolant supply hose assembly from the tooling plate manifold. 5. Remove mounting screws from the tooling plate. 6. Insert one of the mounting screws into each dowel hole, these holes are threaded, and will act as a jacking hole on the top of the hardened dowel. Any other method of pulling the tooling plate off the carriage is not recommended. 7. Remove the tooling plate from the machine.

10.10 CoolPik Sensor Set-up / Adjustment CAUTION! These steps are to be performed after installing the CoolPik plate. Ignoring this procedure may lead to significant equipment/tooling damage. 1. Lockout / Tagout the machine. 2. Remove two orange sensor shields from upper and lower side of CoolPik plenum casting.

3.

Based on the horizontal pitch of the desired mold and tooling plate. a. Remove the mounting screws and relocate the individual sensor plates (which hold the fiber optic lenses) to the matching horizontal pitch locations.



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b. A label is provided to identify the different horizontal pitches 'A' through 'F'. The gray plastic wire duct can be removed to re-route the fiber optic cables.

c. When changing the number of columns being used, only move the inner sensors, instead of the outer sensors i.e. when going from a 6-column mold to a 4-column mold, relocate sensors #2, 3, 4 and 5, and ignore sensors #1 and #6 in the software. The location of the bladders on the CoolPik plate should be used as reference. 4. After the sensor plates are mounted in the correct pitch locations, inspect the location of the sensor vertical line-of-sight with the bladder/cooling pins. 5. Adjust/slide the entire aluminum mounting plate so that: a. the sensor line-of-sight is not blocked by the cooling pins, b. at the same time the line of sight is blocked by the presence of that particular perform on the bladder/cooling pin. The sensing diameter is approximately 5mm, varying with distance (machine size).

6. Open the translucent cover (1) of each sensor amplifier unit (mounted on the rear lower side of the plenum casting) to access the dial (2).

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(2) 7. Adjust the sensor sensitivity/range by turning the orange dial counter-clockwise to decrease sensitivity (full range is 1 to 8). 8. Remove any performs on the bladder/cooling pins. 9. Reduce the sensitivity/range (3) of each sensor amplifier until the LED bars (4) diminish to the last green bar, then turn up the sensitivity/range one half rotation until the LED bars return to maximum. 10.Insert a single preform only on any bladder in that sensor column. 11. Confirm that the LED bars have diminished to the last green bar. 12.Remove the preform and confirm that the LED bars have returned to maximum. 13.Repeat steps 7 to 12 for each sensor amplifier.

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110 10.11Air Picker Maintenance

10.11.1 Pre-Stretching the Air Pickers • Pre-stretching of the air pickers should be performed with all pickers (on a new Cooljet plate) or when pickers are replaced individually. 1. Adjust the air pressure for the air picker, turn the cap (1) until air pressure has reached 50 - 55 psi.

2. 3. 4. 5.

6. 7. 8. 9. 10. 11. 12. 13. 14.

Start up the mold, do not engage the tooling plate/CoolJet at this time. Run machine until part quality is achieved. Allow process to start transfer of parts into the tooling plate. Confirm that all preforms have transferred to the tooling plate, by making a visual observation. • If intentionally a specific cavity is not being shot, the corresponding picker pin with air picker should be removed and plugged with appropriate M(X) bolt. • If unintentionally a preform has not transferred, the corresponding picker pin with air picker should be removed and plugged with appropriate M(X) bolt. Run the mold for 20-30 cycles. Adjust the air pressure for the air picker, turn the cap until air pressure has reached 45 - 50 psi. Run the mold for 150 cycles. Adjust the air pressure for the air picker, turn the cap until air pressure has reached 40-45 psi. Run the mold for 200 cycles. Adjust the air pressure for the air picker, turn the cap until air pressure has reached 35-40 psi. Production can now be started. Check that during steps 2 to 12, air pickers are not inflating without a preform. If preform removal is not affected, lower pressure by 2-3 psi every 3000-5000 cycles.

NOTE:

Air pressure must be set to run as low as possible (below 30psi) to prevent the air picker from bursting, if not supported by preforms.

10.11.2 Installation of Air Pickers

WARNING! Complete the Lockout/Tagout procedure in accordance with applicable local codes before performing maintenance activities. Failure to do so can result in injury or death. 1. Lockout / Tagout the machine. 2. Locate worn air picker (1). 3. Unscrew the picker pin from Cooljet plate. 4. Remove the existing air picker from the picker pin (2). 5. Install new air picker. 6. Reinstall Picker pin to CoolJet plate. 7. Remove Lockout / Tagout.

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11 Startup, Monitor, Shutdown

Objectives • Perform the required steps to safely startup the machine • Monitor machine conditions during operation • Perform the required steps to safely shutdown the machine



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11.1 Filling the Manifold

The amount of plastic in the runner system is usually in the order of 1 to 2 times the shot volume, which means that only after several injections there will be plastic reaching the cavity. To fill the manifold:

1. Close and clamp up the mold. 2. Close the mold valve gates. 3. Bring the injection unit forward against the mold sprue bushing. 4. Manually inject material to charge the manifold and replace any material that may be missing. Watch the injection piston and as soon as the piston slows down release the injection button. 5. Start the extruder and ensure the extruder screw retracts to its back set point.

11.2 Manual Mode Start-up 1. Ensure Dryer is loaded and adjusted to the proper operating temperature. 2. Ensure mold enclosure de-humidifier, air compressor and tower water supplies are ON. 3. Ensure Chiller is on and adjusted to the proper operating temperature. 4. Turn ON the Mold Cooling.

5. Turn Machine Heats ON.

Machine Heats Enable

6. Turn the Mold Heats ON (manifolds and sprue bushing) to the specified start up set points as indicated in the setup guide, approximately 45 minutes before running the system.

Mold Heats Enable



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7. Turn HYDRAULIC PUMP ON.

8. Turn ROBOT POWER ON. 9. Ensure all relevant alarms on the Alarm screen are reset.

10. Open the mold.

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11. Turn HYDRAULIC PUMP OFF.

WARNING! Do not look directly into the cavity. When working in the molding area ensure personnel are wearing the correct personnel protection equipment. Unexpected release of resins may cause serious burns. 12. Check that all mold cavities and surfaces are clean and free of plastic debris. 13. Allow all the Machine Heats to reach their operating temperature. 14. When the Mold Heats have reached their setpoint, enable the valve gate air selection. 15. Allow the mold heats to remain at the start up temperature for 15 minutes before running the system. 16. Start the HYDRAULIC PUMP.

17. Open the feed throat of the hopper.

Hopper Open



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18. Start the SCREW and make sure it fully recovers to the Extruder Back Setpoint.

WARNING! Explosion hazard - risk of serious injury. Molten material at high pressure can be present. Wear PPE. Clear the area of all non-essential personnel. Never purge the barrel when the nozzle tip is outside the purge guard.

20. Purge the shooting pot. Immediately afterward, start the screw as the screw begins the transfer motion. 21. When the screw has recovered again, repeat the purging procedure until the purged melt quality is visually acceptable and free of bubbles and degradation.

CAUTION! If the hot runner is equipped with 268W heaters, (identified by label on hot runner backing plate) the machine heats should be set according to the Set-Up Guide. Failure to do so will cause severe damage to the hot runner.

22. Start the Mold Nozzle Tip Heats at set point and time referenced in the SET UP GUIDE - "Mold Start up Parameters" . Allow the mold nozzle tip heats to soak for a minimum of 5 - 7 minutes.

WARNING! Burn hazard - risk of serious injury. While purging plastic, there is a danger of hot plastic spraying from the nozzle and causing burns. Make sure the injection area is clear of personnel and wear PPE to guard against burns. 3. During Nozzle Tip Heat up time, remove purged plastic from the machine and ensure the mold sprue bushing is free of plastic buildup. 4. Close the MOLD and CLAMP-UP. 5. Select MAINTAIN CARRIAGE FORWARD. 6. Press CARRIAGE FORWARD until the machine nozzle tip contacts the mold sprue bushing.

7. Check the VALVE STEMS are energized closed. Manually INJECT into the hot runner to "pre charge". Immediately after the injection piston stalls, release INJECT and start the SCREW.

8. Open the mold



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29. Disable Cycle Compression. 30. Decrease Injection Pressure Limit to 1000 psi/70 bar.

31. After the Nozzle Tip heat up time has expired, perform the following: A. Press SEMI. Make sure Ejector is disabled (light off). Press CYCLE START. B. After cycle is complete, switch to MANUAL and ensure all preforms have been properly molded (If not, clean cavities as necessary).

C. Eject preforms off cores. Ensure all preforms have been ejected (If not, clean cores as necessary).

D. Repeat Steps A to C until all preforms have been properly molded and ejected.

11.3 Switching to Semi Automatic Mode/Robot Engagement/Auto 1. When satisfied with manual mode conditions, set the machine to semi-automatic mode. 2. Push mold close to begin the start of one cycle, ending with the mold in the open position. This step may be repeated many times to: a. Become familiar with the machine’s sequence of events, b. Flush out any material in the hot runner.

Robot Engagement 1. Check that the tool plate and CoolPik are clear of preforms. 2. Select, Robot Engage on the HMI. 3. Confirm ejector is in Auto mode. 4. Select, Core Air Blow Automatic mode. 5. Select, Semi Automatic Cycle mode. 6. Press cycle start two times. Cycle Start process: a. Press once, CoolPik goes to home position. b. Press second time, mold closes. 7. Perform 3 semi automatic shots. 8. Select Auto. 9. Press Cycle Start.

Switching to Automatic Mode 1. Switch to fully automatic mode when satisfied with the semi-automatic function. This switch can be used to start a cycle (from manual or stopped position - end of semi-automatic) or while the machine is in mid-cycle (e.g. while the machine is in the middle of a semiautomatic cycle). NOTE: It is necessary to press mold close to initially close the mold. With the machine running fully automatic mode, changes to the set-up or processing can be made. 2. Set manifolds, sprue bushing and tip temperatures to operating levels as recommended in the Set-UP Guide, once auto cycling begins. 3. Monitor to create an optimum preform. 4. Settings should be adjusted to the most efficient setting achievable, without freezing off any of the gates. See Power Fluctuation, page 2-7, regarding the need for a constant supply voltage to maintain the gate operating quality.



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11.4 Monitor Machine Conditions during Operation Key Points • Cycle Time Breakdown • Graph Screens - Overview - Clamp - Injection - Recovery • Valves Status Screens - Clamp - Injection - Mold Functions • Statistical Process Control (SPC) - see Husky course T0401 - Statistical Process Control

11.4.1 Cycle Time Breakdown CycleTime Breakdown

Machine Specifications Start Mold Closing Shutter In Clamp Up Unclamp Shutter Out Mold Opening Ejector Forward Ejector Back Mold Open Cooling

0.00 0.27 0.38 4.34 4.57 4.67 5.00 5.96 5.22 3.34 Carriage Forward 0.46 Nozzle Open 0.92 Injection Fill 1.02 Injection Hold 2.23 Pre-Pullback 0.00 Screw Run 5.94 Post-Pullback 0.82 Cycle Time 0.00

0.27 0.10 0.22 0.23 0.10 0.54 0.76 0.31 1.06 1.00 1.52 0.10 1.20 1.10 0.00 117 0.09 6.28

0.27 0.10 0.21 0.24 0.10 0.54 0.76 0.31 1.06 1.00 1.52 0.10 1.21 1.10 0.00 1.17 0.10 6.28 0

4.0 Current Saved

Cycle Time Limit 10.00 s

Key Points

Start and Duration

Duration

0.00 0.27 0.38 4.34 4.58 4.68 5.01 5.97 5.23 3.34 0.46 0.92 1.03 2.23 0.00 5.94 0.82 0.00

Graph

10/19/00 10:48:46 PM

8.0

Part Removal Process Clamp 1.06 3.74 1.48

Process

59.6%

Clamp

23.2%

• Checked boxes - event has occurred in current cycle • Red event - event which is in progress • Green values - saved when cycle has been properly setup, producing good parts • Red values - current cycle • Display Options (pulldown list) - Start and Duration - Duration - Start - Name Only • Pie Chart - Clamp: Cycle Time - Process Time - Part Removal Time - Process: (Start of Cooling + Cooling Duration) - (Start of Clamp Up + Clamp Up Duration) - Part Removal: Mold Open Duration

Part Removal 16.9%



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11.4.2 Overview Graph Key Points • • • • •

Plotting Control Keys (Run, Pause, Stop) Cursor Display Key Curve Selection Graph Properties (visible grid, plot direction) Plot Configuration (color, width, style, scale for individual lines) • Sample Selection - Time - single cycle or multiple cycles - Position - based on position of moving platen (if Stroke Position is displayed) or injection piston (if Injection Position is displayed)

Stroke Pressure

Injection Pressure

Stroke Velocity

Injection Velocity

Stroke Position

Injection Position

Clamp Tonnage

Screw RPM

11.4.3 Clamp Graph Key Points • • • • • • •


Mold Closing Mold Opening Clamp Current Cycle Saved Cycle Current Values Display Legend


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11 Startup, Monitor, Shutdown 11.4.4 Injection Graph Key Points • • • •

Hold Curves Inject Curves Current Cycle Saved Cycle

11.4.5 Recovery Graph Key Points • Screw Speed • Back Pressure • Screw Position

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11.4.6 Valves Status Key Points • Devices - Y - Valve - S - Switch - B - Sensor - P - Pump • Valves - DQ - Digital Speed - DP - Digital Pressure - SD - Servo • Feedback Devices - PX - Proximity Switch - PT - Pressure Transducer



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11.5 Shut Shutdo down wn 1. If system downtime is expected to be more than half an hour, decrease the Dryer temperature to approximately 120°C/250°F. If system downtime is expected to be more than 3 hours, decrease the Dryer temperature to approximately 80°C/175°F 80°C/ 175°F.. Consult with your resin supplier for recommended settings. 2. Immediately after completing step 1, close the feed throat of the hopper. 3. Allow the machine to run 2 cycles, then perform the following: A. Switch to SEMI mode.

B. Press Pr ess CYCLE CYC LE START. START.

C. Repeat Steps A and B until the shotsize no longer recovers. 4.When the last cycle has been completed, switch to MANUAL mode.

5. If system downtime is expected to be less than one half hour, Enable Mold Heats Stand-By to 180°C/350°F. If system downtime is expected to be more than half an hour, turn Mold Heats OFF.

WARNING! Burn hazard - risk of serious injury. While purging plastic, there is a danger of hot plastic spraying from the nozzle and causing burns. Make sure the injection area is clear of personnel and wear PPE to guard against burns. 6. Press CARRIAGE RETRACT until sufficient clearance for purging has been reached, then purge any remaining material from the Shooting Pot/Screw. 7. If system downtime is expected to be less than half an hour, Enable Machine Heats Stand-by to 180°C/350°F. If system downtime is expected to be more than half an hour, turn Machine Heats Off.



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8. Disable the valve gate air selection.

9. Extend Ejector plate forward.

10. Turn OFF Hydraulic Pump.


11. Lockout / Tagout the machine power source. 12. Clean out any water or small pieces of plastic on the mold. If system downtime is expected to be longer than 6 hours, spray the molding surface with petroleum based spray, i.e. LPS2, to prevent corrosion.

13. Remove Lockout / Tagout. 14. Turn ON Hydraulic pump.

15. Retract Ejector plate.

16. Leave the mold open with the dehumidification system running. Continue to circulate cooling through the mold and machine with gates closed. 17. When the hot runner temperature is below 100°C/212°F, turn OFF mold cooling and/or chiller.

18. When the mold reaches room temperature, and no condensation appears on mold, close the mold (do not apply clamp tonnage).



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19. Turn OFF Hydraulic Pump.

20. Turn OFF tower water supply and air compressor as necessary.

21. Turn OFF mold enclosure dehumidifier when the mold reaches room temperature.


22. Lockout / Tagout the machine power source.

11.6 Test for Understanding 1. Perform all steps to safely startup the machine 2. Perform all steps to safely shutdown the machine. 3. On the Mold Setup screen, how many Setups have the same Mold ID and the same Resin Type? __________ 4. Save the current Setup to an empty slot in the Machine Memory. Save the current Setup to an empty slot in Portable Memory. Copy a Setup from the Machine Memory to an empty slot in the Portable Memory. Delete the Setup which you saved to the Machine Memory. 5. Capture the Cycle Breakdown screen from the machine. The instructor will display the screen on the projector, use the screen to answer questions 6-10. 6. How is the machine performing as compared to the saved cycle? Worse

Same

Better

7. Which event takes the longest amount of time to perform? _______________ 8. Does the ejector forward motion start before the mold is open? YES NO 9. What percentage of the cycle is used for Mold Opening and Closing? ______ 10. If the Cycle Breakdown for the current cycle is different from the saved cycle, discuss the following: - Is the machine producing quality parts? - Is the current cycle faster or slower than the saved value? - Which event or events are responsible for the cycle difference? - According to plant procedures, how will the difference be resolved (adjust current cycle, perform maintenance, or save current cycle)? 11. If the answer to question 3 is greater than 1, which Setup is the correct one?_________ How do you know?



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Glossary Absorb

To take up or receive in by chemical or molecular action.

Acetaldehyde

A gaseous byproduct generated in extremely small quantities during the manufacture of PET chips and extrusion of PET bottles and films. Acetaldehyde levels in PET containers are important for product taste integrity only and not a product safety or health concern.

Alkyl

A general term for monovalent aliphatic hydrocarbon radicals which have been derived from an alkane by dropping one hydrogen from the formula.

Amorphous

Noncrystalline, having no determinable form or crystalline structure. Amorphous polyester (PET) is clear in appearance.

Anneal

The process of inducing crystallinity by the prolonged application of heat. Subjection of formed object to heat followed by slow cooling to toughen.

Biaxial Orientation The process of stretching a hot plastic film or other articles in two directions under conditions that result in molecular realignment. Birefringence

A change in index of refraction with direction. Birefringence is evidenced by the ability of a material to rotate the plane of polarized light. In crystalline polymers birefringence is made up of contributions from the crystalline and amorphous regions plus a contribution due to the shape of the crystals or the presence of voids.

Blow-up Ratio

The ratio between the diameter of a blow molding preform and the maximum diameter of the cavity in which it is blown.

British Thermal Unit (BTU)The amount of heat required to raise one pound of water at maximum density through 1 oF Burst Strength

A measure of the force necessary to cause a container such as a bottle to burst. Burst strength is related to the tensile strength of the polymer.

Carboxyl

COOH substituent characteristic of all organic acids. In PET, the end of the polymer chain can be terminated by either a hydroxyl or a carboxyl high temperature and moisture conditions.


Glossary

135

Hopper Loader

A device device for automatically automatically feeding feeding molding powder to hoppers hoppers of of extruders, extruders, injection injection molding machines and the the like. like. The functions of drying and blending colors with the molding powders are also sometimes accomplished by loaders. There are two general types of hopper loaders: mechanical and pneumatic. The mechanical systems use a rotating screw in a tube, or a conveyor belt on which are fastened small containers which dump their contents into the hopper.

Hot-Runner Mold A mold in which the runners and secondary secondary sprues are kept kept hot and and fluid during the the entire entire cycle and are not ejected ejected with the molded part. This avoids the need for handling and reprocessing scrap normally generated from runners and sprues. Hot-Runner System The runner is the channel that carries molten polymer from the extruder to the mold. In a hot runner system this channel is heated and only the molded part is ejected after each shot. The hot polymer in the runner system is incorporated in the next part to be molded rather than as scrap to be removed. Hydrolysis Hydrolytic

A chemical chemical process in which water water acts acts upon another another substance substance to form one or more more entirely entirely new substance substances. s. Related to or causing hydrolysis (see hydrolysis).

Hydrolytic Degradation The reaction between a polyester and moisture which results in the cleavage of ester bonds and the loss of molecular weight and physical properties. Hygroscopic

Absorbs water readily readily..

Injection Blow Molding A blow molding molding process process in which the preform preform is formed formed over a mandrel by by injection injection molding, molding, after which the mandrel and preform are shifted to a blow mold where the remainder of the cycle is completed. While the part is being blown, cooled and ejected, another preform is being injection molded. Advantages of the process are that a completely finished part is formed requiring no post finishing operations, closer tolerances are possible, and preform wall thickness can be varied at desired areas. Injection Mold

A mold used in the process process of injection molding. The mold usually comprises two sections sections held held together together by a clamping device with sufficient strength to withstand the pressure of the molten plastic when injected, and is provided with channels for heating, cooling and venting.


Glossary

137

Organoleptic

Relating to taste or odor.

Orientation

Molecular chains of a polymer arranged relative to one another. Parallel orientation of polymer chains gives improved strength to materials such as polyester (PET).

Oxygen Permeability

The measure of the rate that oxygen will flow through (permeate) a film.

Parison

The initial extruded form produced in extrusion blow molding. Sometimes used interchangeably with preform.

Paraxylene

The aromatic stream extracted from crude oil which is used to synthesize terephthalic acid.

PCO Thread Finish(Plastic Closures Only) That portion of the top of a PET preform that constitutes the threads for the cap to screw onto. Typically for beverage bottles, this will be defined as a 28mm or 38mm PCO finish depicting the diameter of the opening. The PCO thread finish is lighter in weight than it’s corresponding size Alcoa thread finigh, and the PCO finish can be delineated by observing discontinuities in the threads which act as vents for C O2 escape through when a carbonated beverage bottle cap is removed, as opposed to vent “slots” as seen on Alcoa finishes such as the 1716 or the 1820 series finishes. PCR

(Post Consumer Regrind) Polymer reclaimed as recycled post consumer materials (typically bottles or containers) that is ground up and re-used in the extruder.

Pearlescent

A white appearance resembling that of pearls.

Permeability

The measure of the rate that a gas will diffuse through a polymer film or any other membrane.

Permeant

The gas which permeates through a polymer film.

PET

Acronym for polyethylene terephthalate.

Plasticizer

A small organic molecule used to soften a plastic.

Polyester

Generic name for a large group of synthetic resins produced by reacting dibasic acids with dihydric alcohols.

Polyethylene Terephthalate

PET, polyester resin formed from the polymerization of ethylene glycol and terephthalic acid.

Polymer

A substance, usually synthetic, composed of many monomers linked together (polymerized) in a long chain.

Polymerization

Formation of large molecules (polymer) by union of a number of simple molecules (monomer). Polyester (PET) production occurs by the condensation polymerization of reactive monomers with the elimination of by-product or excess monomer.

Preform

As pertaining to PET containers, a form produced by injection molding. Preforms are further processed by either stretch blow molding (reheat blow molding) or injection blow molding to form the finished container. Also see parison.


Glossary

139


Glossary

140

Quench

Refers to the freezing-in of amorphous polymer structure, or the freezing-out of crystallinity.

Ram Travel

The distance the injection ram moves in filling the mold in injection or transfer molding.

Refractive Index

The ratio of the sine of the angle of incidence to the sine of the angle of refraction for a ray of light passing through the surface separating two media.

Regrind

Polymer scrap created during processing that is ground up and reused in the extruder.

Reheat Blow Process The process where containers are manufactured by first molding a preform and then reheating the preform and blowing it into a container. Resins (synthetic) Amorphous, organic, semi- solid, or solid materials formed by the union of a large number of molecules of one, two, or three relatively simple compounds in polymerization or condensation. Rheology

Study of the deformation and flow of matter under conditions of stress, strain and time.

Screen Pack

A filter added to a line carrying a polymer melt for the purpose of removing particulate contamination. (As pertaining to the processing of PET containers, a force which can, during extrusion, promote the degradation of polyester.)

Shot Capacity

Injection capacity of an injection molding machine.

Specific Heat

Quantity of heat required to raise temperature of unit mass one degree.

Solid State Process A manner of referring to secondary polymerization (following melt polymerization) used in the manufacture of polyethylene terephthalate (PET) resin. An economical method of achieving high molecular weight (i.e. IV greater than 0.70). Specific Volume

The reciprocal of density.

Spherulite

A spherical aggregate of crystalline polymer, ranging from submicroscopic to millimeters in size.

Sprue

The first part of the runner system. The first section after the extruder that takes hot polymer from the extruder to the mold.

Stretch Blow Molding

See reheat blow process.

Terephthalic Acid A dibasic acid in the form of white crystals or powder. It is formed by oxidation of paraxylene or other alkyl aromatics using metal salts and bromine as catalysts, or by the reaction of benzene and potassium carbonate over a cadmium catalyst. A raw material used in the manufacture of PET. Tc

Temperature of crystallization.

Tg

See glass transition temperature.

Thermoplastics

Usually synthetic resins that may be softened with heat but then regain original property (form) on cooling.

Take-Off Equipment

Equipment used to hold or convey sheeting for secondary processing, such as thermoforming.

Tensile Strength

The strength of a material when a stretching stress is applied to a test sample. The material may show a yield or a break.

Tensile Modulus

The slope of the stress strain curve at a given strain.

Thermoelastic

A material which will flow at temperatures above the glass transition temperature.

Thermoplastic

Soft and pliable whenever heated without any change in inherent properties.

Tm

Melting Temperature. The temperature at which the polymer melts. Usually the maximum of the temperature range over which a polymer exhibits melting behavior.

Ultimate Elongation

The elongation at rupture in a tensile test.

Uniaxial

Refers to deformation in one direction.

Unoriented

refers to a sheet or fiber which has not been stretched or drawn in any direction.

Viscosity

The "thickness" of a material. A measure of how readily a material (usually a liquid) flows.

Virgin Resin

Resin which has not been previously processed.

X-ray Diffraction

A method of studying a material's crystal structure by studying the pattern of X-rays scattered from the material when exposed to the X-ray radiation.

Zero Shear Melt Viscosity


The melt viscosity extrapolated to conditions of zero shear.

Glossary

141


Glossary

142

HyPET Operator Course

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