The model P-212111-E-M-22161502426-XXXX dip-molding machine is an eight station, turret style (rotary), microprocessor controlled machine. Eight similar or dissimilar products can be processed at the same time by use of independent arm controls. The enhanced Human Machine Interface and PLC work together to store and process parameters at each station of the machine during a given cycle. The advancing product is kept track of and parameters such dip speeds, dip lengths, dip dwell times, cure times, cooling times etc., follow the product and adjust the machine cycle. All of these parameters can easily be stored, under a given file name, and recalled at any time. Production count is verified through the HMI.
Both preheat and cure heating is by electric heating with both infrared and convection heat transfer. Air re-circulation across the heaters is all within a closed loop system for each oven bay. Control of the oven air temperature is by PID control with solid state power controls to accurately proportion the heater outputs. These features not only assure maximum energy efficiency, but also, maximum heater and component life. Temperature control is also included (to control the customers valve) for all four dip tanks. The HMI will display and/or store oven and dip tank temperatures for current or future reference.
Automatic mold lubrication (water based) is a standard feature on this machine. After part removal or striping, the operator can select “lube or no lube” before the next index. If lube is selected, the mobile lift at the lube station will raise the tank (included with the lift) containing the mold lube, after the turret cycles, at the programmed speed, to the programmed position, for the programmed length of time. This same system can be used for priming parts (water based) that are to be plastisol coated. A separate primer tank is recommended.
Up to 4 plastisol colors or grades can be processed during machine operation. Operator programming can cause the preheated mandrel or part to removed from the arm at the dip station and transferred quickly to one of four dip tanks. Up to three subsequent dips (depending on resident heat storage of the tool) can be made in any of the other dip tanks. Vertical speed and positioning is very accurate because of the accuracy of the closed loop servo system. Up to 5 profiles moves (speeds, positions, and dwell times) are available at each of the four dip stations. Ultimate wall thickness and drip control is achieved by this added flexibility. The molded parts are quickly returned to the dip station then rotated to the curing oven.
Dip tanks can be fitted with heat exchangers and the plastisol temperature can be controlled with PID controllers working with heated and or chilled water supplies. Of course this data can be displayed and / or stored for current or future use also. Dip tanks usually use a combination of agitation, re-circulation, and closable dams to maintain accurate temperatures and liquid level. The machine is programmed to synchronize the operation of the agitators, re-circulation pump, and dam gate so that dipping is performed in very stable and stationary plastisol. This operation assures maximum dip length accuracy and precise dip lines.
The “brains” of our machines is the programmable logic controller (PLC) microprocessor and the “brawn” is the cam indexer that precisely and expeditiously rotates all the arms to the next station. Typically, the index cycle (unproductive time) can be less than 5 seconds. Other included features include the central lubrication system and automatic plastisol replenishment for each dip station. The HMI also includes programming, hardware, and software for remote access or control of the equipment (via modem). This feature allows upgrades or troubleshooting from the factory.
*Preheat Bays- 2
*Dip Station- 1 (for use with the included 4 station overhead dip system)
*Cure Bays- 2
*Cooling Bays- 1
*Unloading Stations- 1
*Lube stations- 1
NEMA electrical enclosures
415/50/3 power at 200 amps full load (expect 50-60% of full load after machine is warm)
Compressed air – 120p.s.i. @ 30 cfm
Water for cooling tank
Preheat Heaters – 61.2 kw
Cure Heaters- 64.8 kw
(4) Re-circulation blowers – 2.7 HP ea.
Cooling and Lube lifts – 1 HP ea. Variable Frequency speed control with analog feedback for positioning
Dip station X-axis – ½ HP Variable Frequency Drive with analog feedback for positioning
Dip station Y-axis - ½ HP Variable Frequency Drive with analog feedback for positioning
Maximum Rack Size – 24” wide x 26” long (20.5” x 26” tooling area)
Maximum dip length below bottom of arm – 16”
Clearance from bottom of arm to oven ceiling – 6”
Maximum weight of tooling per arm – 150 pounds
Temperature control for preheat and cure ovens by PLC PID control and Watlow Din-a-mite SSR
One control zone for preheat and one control zone for cure.