The model P-211101-E-II-21142002426-EGLWP is a 10 station, turret style, microprocessor controlled machine. The design allows similar or dissimilar products to be plastisol coated. Up to two colors or grades can be processed in one machine operation. Double dipping is easily achieved because of the post heat oven between the two dip stations. When used as a single dip machine, the post heating oven can function as an addition cure oven, which will usually reduce overall cycle time. This machine can be used for coating products as well as mandrel dipping.
Sequence of Operation
The process begins with loaded racks placed on the machine by the operator. During the first two cycles of operation, the parts will pass through high temperature preheat ovens to elevate the substrate temperature before reaching the first plastisol dip station. After the dip station, the arm loaded with dipped parts will enter the post heat oven. A second dip station for double dipping is next in line. When single dipping, there is a lot of flexibility in using the post heat oven either as a preheat or cure oven to reduce cycle time. Then the dipped parts enter the first of two cure bays. When the parts emerge from the 2rd cure bay, they are available for cooling. A programmable water quench system takes care of this stage. The unloading/reloading station is next. A safety light curtain is in place at this station to shut down turret operation in case the area is not cleared prior to elapsed cycle time. Typically an optional conveyor is used at this station to send the stripped parts to one of 10 packaging areas. After the turret indexes to the next station, an automatic lube station (identical to the water quench station), coats the tooling with a water based release agent. The lube station is fully programmable with speeds and dwell times just like the quench station. When coating parts, the lube tank can easily be replaced with a similar tank (optional) that contains a water based primer. This aids in obtaining a good bond between polymer and metal.
The programmable logic controller (PLC) will allow independent cure, plastisol dip, cooling, and lube/prime parameters for each arm. The products (up to 10) are tracked and parameters reset as the product advances from stage to stage. Total versatility at dip stations allows dipping at dip tank one, dip tanktwo or both. Ten profiles (speed and position) are available for each dip station.
The preheat, post heat, and cure heating is by electric heat in combination with air turbulence to assist in even heat transfer to the molded part. A closed-loop air circulation system is standard. Fixed lifts (as opposed to mobile lifts) are included for plastisol dipping. This new design uses hardened profile rails and linear pillow block bearings to allow maximum smoothness and long life. Both plastisol (dip) lifts also use the fastest and most accurate motion control system available. Servo systems on the dip lifts, with closed loop feedback, give repeatable accuracy of plus or minus .003 inch and speeds from 5 inches per minute up to 244 inches per minute. Pneumatic leveling is included at each dip station to achieve accurate leveling prior to dipping. Agitation of the dip tanks is by variable speed motors fixed to the lift. This eliminates the need for agitator motors on each dip tank thereby reducing the cost of each dip tank. The turret is accurately and quickly positioned with a cam indexer and DC variable speed drive. An electronic overload protection device is included that will shut down the indexer in case obstructions jam the rotation of the turret. This protects the mechanics of the indexer and avoids other damage to the arms or tooling. An emergency reverse switch is located inside the main electrical panel to quickly reverse the turret (even in the e-stop mode).
All machines include a central lubrication system to lubricate all critical points from a single lube pump. The Diagnostics feature of the HMI will warn the operator when to perform this quick and easy task. This system can be upgraded to a completly automated centralized lube system.
Approximately 240” x 240”
Maximum tool sizes
Rack size 24” x 26”
Weight 200 pounds per arm
Maximum dip length 14”
Maximum preheat temperature 650 deg. F
Maximum post heat temperature 650 deg. F
Maximum cure temperature 650 deg. F
Electrical Preheat heaters 61.2 kW max.
Post heat heaters 32.4 kW max.
Cure heaters 64.8 kW max.
Circulation blowers 5 @ 3HP
Door operators 6 @ 1/2 HP
Turret Drive Cam indexer with DC variable speed
Fixed lift drive Servo, constant torque from 0-4000 RPM
Dip Agitation 3 HP variable frequency drive
Total maximum load (startup) 220 Amps @ 440/3/60
All control voltages via step down transformers (included)
Preheat- Solid-state relay, digital PID control with separate high temperature alarm with heater burnout monitor.
Post heat- Solid-state relay, digital PID control with separate high temperature alarm with heater burnout monitor.
Cure heat- Solid-state relay, digital PID control with separate high temperature alarm with heater burnout monitor.
- Independent timers for cycle, plastisol dip dwell, cooling, and lube for each arm.
- Independent dip counters for each arm and each dip station.
- Dip off control for each arm for dip station one.
- Dip off control for each arm for dip station two.
- HMI (Human-Machine Interface) Operator interface