宝洁公司注塑成型车间培训资料.doc

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1、Operating and Preventive Maintenance Guidelinefor High PerformanceInjection Molding高效注射成型的操作与预防保养指南NOTE31SAFETY GUIDELINE 安全方针32MOLD SET-UP PROCESS 模具上模程序53HEATING-UP PROCESS 加热程序64START-UP PROCESS 开始程序75DURING PRODUCTION 生产过程86COLOUR/MATERIAL CHANGE 换色/换料87MAINTENANCE 保养87.1General 概要87.2Shift chan

2、ge 日保养97.3Weekly 周保养 97.4How to clean the mold 如何清洁模具98TAKING OUT OF SERVICE 下模保养 108.1For short term 短期108.2For long term (3month) 长期（3个月）109MALFUNCTION 故障119.1 In case one cavity blocked 万一有一穴堵住119.2Loss range of tolerance by plastic parts 产品偏离公差范围119.3Get a noisy screw (injection unit) 螺杆有噪音（射出单元

3、）119.4Black dots 黑点119.5Deviation of part wallthickness 产品壁厚偏差 1210GENERAL INSTRUCTION 通用作业指导书12Note 注释To assure warranty of fitness for best mold function and best part quality: 为确保最佳的模具功能和最佳的产品质量的合理的依据All cleaning, service or maintenance intervals have to be documented by responsible person! 所有的清洁

4、，维修与内部保养，责任人须将其文件化Nobody can expect a highly part quality if the mold is dirty, worn out, wrong adjusted, badly mounted, not properly cooled, molding parameters are not adjusted according to material data sheet or other related devices are not working properly.如果模具脏污，破损，错误的调整，安装不好，不正确的冷却，工艺参数不是按按照材料

5、的性能数据表设定，或其它的辅助设备工作不正常，就不可能得到合格的注塑产品。Any recommendation for guideline improvement or missing items within this document are welcome! 对本指南尚需改进的地方或疏漏之处，欢迎提出宝贵建议！1Safety Guideline 安全方针Before proceeding please read the details of this guideline carefully to avoid mold or machine damage or accidents by m

6、ishandling the mold or equipment or the machine control or the molding machine itself! 为避免错误的操作机器或设备，或模具，或机器控制系统，导致模具或机器的损坏或事故，请在进行操作之前仔细的阅读本指南。1.1Before operating the mold or/and control system a specialist should check all electrical connections. It should match local requirements or guidelines fr

7、om your company (e.g. hot runner connection!) 。 在操作模具或机器控制系统前，必须由专业人员检查电器的连接，机器或模具必须与工厂内的要求或指导方针相一致（比如热流道的接线方式）1.2Never bypass an electrical fuse. 任何情况下，不能对保险丝连接旁路。1.3Avoid any water contact of any electrical connector or device! 避免水接触到电子连接处或设备1.4In case of water contact it is necessary to dry all p

8、arts carefully before putting into operation again! 万一水接触到电子元器件，在运转之前 ，首先将湿的零件擦拭干燥好。1.5?After any interruption or break of molding process the mold should heated-up smoothly with reduced temperature to get all heaters dried of existing condensation water soft drying process. 生产中断后，应该慢慢升高模温，以用来除去冷凝水。

9、1.6?In countries with high air humidity level, the heating-up process has to be done with delayed temperature increase every time before start running this is to assure a dry system and to remove existing condensation water from the system. 在高湿度的地区，在开始之前应使用延迟加热，这是为了确保一个干燥系统和除去系统中存在的冷凝水1.7.All screw

10、connections have to be checked before operating (mold plate, ejector unit, inserts, pressure plates, etc.). 运转前，必须检查所有的连接的螺丝（如模板，射座，型芯上的）1.8After every interruption or break of production check the mold movement areas and assure that the slider are at the right position. 每次生产中断后，须检查模具动作的区域，确保滑块在正确的位

11、置1.9Before demounting the mold all safety parts have to be assembled , i.e. ejector plate lock or mold protection lock. 在下模之前，所有的安全部件必须装上，如顶板锁定块，模具保护块等。1.10Weekly check of all cooling/heating hoses. Exchange brittle pipes/hoses! 每周检查冷却/加热的软管，更换变脆的软管。1.11Weekly all couplings of the hoses have to be c

12、hecked for proper safety function. 每周检查管路的快速街头是否脱落，确保操作者安全。1.12Daily check the ejector coupler for tight fit. 每日检查顶杆连接处的固定情况1.13 Daily check the ejector stroke for correct adjustment. 每日检查顶杆的顶出位置并正确调整1.14Use the set up for the mold protection in this way, that there is no possibility to damage the m

13、old due foreign substance or mechanical reason. The clamping force should to come in effect when the mold plates are in contact. 使用准备模式，可以对模具进行保护，防止因不相关的物质或机械原因，导致对模具的损坏，此时只有在两模板接触到时才会产生锁模力。1.15Never inject into an open mold without purpose or additional protection of mold inserts. 在模具打开且型芯没有外加防护的情况

14、下，禁止向模具内射料。1.16Please wear suitable gloves for cleaning or repairing the mold to avoid injury. 为避免伤害，在清洁或修理模具时请戴上手套。1.17By operating with hot elements or hot-runner elements every time suitable safety gloves must be worn. 每次操作热的元器件或热流道器件，必须戴上合适的安全手套1.18Switch off the voltage to get no risk of manipu

15、lation during a long turn interruption. 在机器长期停止期间关闭电源，以防止给操作者带来危险。1.19Never start running when the safety guard gate is open and never disassemble any safety switch or safety equipment! 禁止在安全门打开时开始操作机器，禁止拆卸任何安全开关或安全设备。 2Mold Set-Up Process 上模程序2.1To get a 100 percent parallelism clean the machine pl

16、ate and the mold plate with a cloth, so that they are free of rust, chipping etc. 为获得100%的平行度，须用抹布清洁机器模板和模具模板上的锈，碎片等。2.2Fix the mold to the machine plate on the injection side with a centering ring, screw it and close the moving machine plate in setup modus (reduce clamping pressure/force; reduce hy

17、draulic pressure). In some cases (handling system or vertical injection unit) adjust the mold with a water level. 使用定位把模具安装在射出侧，用螺丝定位后，在准备状态下（为减小锁模力/压力，液压压力），合上模板，调整模具水平。2.3Calibrate the mold height (setup modus). 在准备状态下，调模厚2.4Screw the mold plate with the moving machine plate. 用螺丝把模具动模侧固定好2.5Open t

18、he mold (setup modus). 在准备模式下开模2.6Couple and than adjust the ejector (setup modus). Avoid that the ejector goes block too the opposite plate. Ensure that the ejector is at the back position. 在准备状态下连接并调整顶杆，避免顶杆卡死。确保能回到正确的位置2.7Connect water, air and electricity. 连接水，气和电路2.8Assure all connections are i

19、nstalled properly. Check with air whether all cycles are connected. 确保所有的连接安装正确，使用气枪检查是否所有的回路都被连接2.9Assure water hoses are not too long or too short, so that there is no overbending or rubbing against any sharp edge or obstacle. 确认水管不是太长或太短，避免弯曲太大或与尖的边缘或障碍物摩擦2.10Switch on the cooling system (control

20、ler) and check that no hose or coupler is leaky. 打开冷却水开关，检查水管与接头无漏水2.11Check that there is no leaky spot in the mold (cavities, mold plates, sliders). 检查模具型腔，模板，滑块是否漏水Note: Any leaky spot can damage the steel due to burning water spot on steel surface! 注：任何漏点都可能因钢材表面的气化水点导致损坏钢材2.12Adjust the right s

21、troke and velocity for the mold. For first setup and first mold closing movement reduce the closing speed to a minimum to avoid and damage (setup modus)! For production also adjust the closing movement to a lower speed when guide pins and angular pins start to proceed. 正确调整模具的位置与速度，第一次模具架模与第一次模具闭合，在

22、准备模式下，降低至最小速度以避免损坏模具。在生产时，当导柱或有尖角的型芯接触时，也须调整锁模速度慢一些Note: Guide pins should be slightly greased, and never run dry! 注：导柱必须涂上适量润滑油脂，禁止无润滑油脂运转2.13Close and open the mold a few times and check whether the movement is correct (setup modus). 在准备模式下，开合模几次，检查动作是否正常2.14Switch on the hot runner according 3.5.

23、 依照3.5章，打开热流道2.15The mold has to be closed during heating process. 在加热过程中，模具应处于合模状态2.16When the mold reaches the required temperature open and close the mold again (setup modus) and recheck the mold height, than add the clamping force (manual modus). 当温度至设定的温度时，再次在准备模式下开合模，再次确认模厚，在手动模式下加上锁模力2.17Only

24、 use water which is neutral (PH-value 7.1-7.5), to achieve water requirements the water has to be treated. 使用的水必须是符合水质要求，经过处理的中性水（PH值在7.1-7.5间）2.18Clean cavities, sliders and parting plane so that they are free from rust, shadows, film layer or other substances. Use suitable rubber to clean all visi

25、ble surfaces on a regular base. 清洁型腔，滑块和分型面以防止模具生锈，产生暗影，形成塑料薄层等。用专用的橡胶笔定期清理模具表面。2.19Adjust a proper mold protection and recheck the settings to avoid any mold damage. 正确调整模具的保护，重新检查设定，避免任何的模具的损坏3Heating-up Process 加热程序3.1Mold has to be closed without clamping force (setup modus). 在准备模式下，合上模具，处于无锁模力的

26、状态3.2Switch on the temperature/cooling control system.Assure all systems are sealed. 打开模温控制系统，确保系统密封良好3.3Switch on temperature controller.打开温度控制器3.4Switch on the hot runner system with delayed heating-up curve. 使用延迟加热方式打开热流道系统，3.5Firstly the hot runner temperature should be adjusted to about 100 deg

27、ree for approx. 10 minutes. This is to assure that a potential humidity layer (condensation water) is evaporated before heating-up to maximum temperature. 首先调整热流道温度到100摄氏度，保持10分钟，目的是为了保证潜在的水层（凝结水）在加热至最高温度前蒸发掉。3.6During the heating-up process check the function of the hotrunner by using the control s

28、ystem (e.g. check current value for each nozzle). Here you can check already whether the hotrunner is properly working and in range of tolerance for each heating zone. 在加热过程中，首先检查热流道的功能（如每个喷嘴的实际值）直到热流道正确工作且每个加热区在公差范围内。3.7Check material datasheet for correct temperature adjustment. 依材料物性表调整温度3.8When

29、the process temperatures (mold, hot runner) are reached adjust the mold height (setup modus), then switch over to manual modus to set-up the clamping force. 当制程温度（模具，热流道）到达后，在准备状态下调整模厚，然后切换至手动模式，设定锁模力3.9Recheck the mold protection (by pressure and time). 再次检查模具保护设定（压力和时间）4Start-up Process 开始程序4.1Sta

30、rt the molding process when all process temperatures are reached.(mold, hot runner, nozzle, barrel). 在所有的温度（模具，热流道）到达后开始注塑制程4.2Before the injection process is going to start, spout few times the aggregate. This is to assure best possible in process material condition. 在注塑之前，空射几次，目的是为了确保最好的材料状况4.3The

31、 machine nozzle has to fit the mold bush correctly (check the position or touch-up with a piece of paper). However, this may vary from different nozzle fitting systems. 机器的喷嘴必须与模具浇口套相配合良好（使用一张纸检查位置与接触状况）4.4For first sampling always start with a filling study. Take care that no cavity is overloaded .

32、 Start with a smooth adjustment. Store the filling study parts. 经常在第一次试模时进行充填分析，注意不可过度充填，开始时进行微调。保留充填分析的样品4.5According to the filling study result try to balance the hot runner nozzles for each cavity. 根据充填分析结果，对每个热流道进行调节以达到平衡4.6After approx. 98 percent fill grade switch over to holding pressure. 大约

33、充填至98%时，转换为保压阶段4.7Holding pressure time depends of gate and part design; Take weight of the plastic parts without sprue to get the correct holding pressure time. 保压时间取决于浇口与产品的设计，通过称量产品的净重以获得合适的保压时间Note: If gate is frozen, no holding pressure will be active in the part and part weight can not be incr

34、eased anymore! 注： 如果浇口已冷却，保压不会再对产品产生效果，产品的重量不会再增加4.8Choose the proper adjustment of injection velocity to fill the cavities, depending of part design, part thickness, mold temperature, surface quality etc. 依据产品设计，壁厚，模温和产品的表面质量，选择合适的充填速度。4.9Choose the proper cooling time to achieve best possible (nec

35、essary) part quality. 选取合适的冷却时间以获得最优的产品品质4.10Check the part quality (surface, sink marks, joint lines, shrinkage, warpage, etc.) 检查产品的质量（表面外观，缩水，结合线，收缩，翘曲等）4.11Pay attention that the sprue and plastic parts are easy to release during ejection stroke. 注意产品在顶出过程中，料杆与产品是否容易脱模4.12 In cases there are sti

36、cking plastic parts at the core only use cooper or brass to force thes parts.万一有产品粘在型芯上，只能用紫铜或黄铜工具去除5During production 生产过程5.1The ejector plate should not go block. 顶针板不可被卡死5.2Avoid that there is jammed plastic material in any mold area. 避免在模具的任何地方存在压碎的塑料原料5.3Choose the injection pressure and time t

37、o avoid overstress in the mold. 选择合适的射出压力与时间，以避免过度充填5.4 Check the cooling water temperature and the flow rate.检查冷却水的温度与流速6Colour/material change 换色与换料6.1Stop the material supply. 停止原料供应6.2Produce until the screw doesnt reach the plastification stroke. 继续生产直至螺杆无法达到计量位置6.3Clean the hopper, the nozzle

38、and the feed bush 清洗原料储料筒，喷嘴和浇口套6.4Spout aggregate until the extrusion material is clean/ regular 射料直至射出的料已干净/正常7Maintenance 保养7.1General 概要7.1.1Check all screws of injection mold. 检查模具上的所有的螺丝7.1.2Check whether the ejector unit is loose. 检查顶出杆是否松动7.1.3Inspect couplings, water hose and hydraulic hose

39、 whether they are leaky. 检查接头的连接，水管各液压管路是否泄漏7.1.4Check control systems, i.e. hot runner system, cooling system. 检查控制系统，如热流道，冷却系统7.1.5Check mold protection adjustment (time and pressure). 检查模具保护的时间与压力7.1.7Inspect regular all machine parameters, i.e. back flow blockade, pv-regulator; take care for it.

40、 定期检查机器的参数，如止逆阀，7.1.8Check air system for leackage. 检查气路是否泄漏7.1.9Take care that there are no foreign parts or plastic parts between the parting areas or between sliders, ejector plate, etc. 检查产品成型型芯，滑块间，顶板间，没有其它无关的物品或料料产品7.2Shift change 日保养7.2.1Clean working area. 清洁工作区域7.2.2Clean cavities and parti

41、ng surfaces. 清洁型芯和分型面7.2.3Compare molding data sheet with set up. In case of some deviations please make documentation. 比较设定值与实际值，如果有不同的冲突的地方，进行文件更改7.3Weekly 周保养7.3.1Clean guiding elements and renew if necessary all lubrications. 清洁导向部件，必要时更换润滑油7.3.2Disassemble and clean slider, core and stripper plate. 卸下滑块，型芯和顶出板并清洁7.3.3Inspect the cooling system, check the water flow rate/ pressure. 检查冷却系统，检查水压及流量7.3.4Check the water qua