寶潔公司注塑成型車間培訓(xùn)資料

VersionVersion1.0/ToolTechnologyBSL#OperatingandPreventive

MaintenanceGuidelineforHighPerformanceInjectionMolding高效注射成型的操作與預(yù)防保養(yǎng)指南NOTE31SAFETYGUIDELINE安全方針32MOLDSET-UPPROCESS模具上模程序53HEATING-UPPROCESS加熱程序64START-UPPROCESS開始程序75DURINGPRODUCTION生產(chǎn)過程76COLOUR/MATERIALCHANGE換色/換料87MAINTENANCE保養(yǎng)87.1General概要87.2Shiftchange日保養(yǎng)87.3Weekly周保養(yǎng)97.4Howtocleanthemold如何清潔模具98TAKINGOUTOFSERVICE下模保養(yǎng)98.1Forshortterm短期98.2Forlongterm(>3month)長期（>3個月）109MALFUNCTION故障109.1Incaseonecavityblocked萬一有一穴堵住109.2Lossrangeoftolerancebyplasticparts產(chǎn)品偏離公差范圍119.3Getanoisyscrew(injectionunit)螺桿有噪音（射出單元）119.4Blackdots黑點(diǎn)119.5Deviationofpartwallthickness產(chǎn)品壁厚偏差1110GENERALINSTRUCTION通用作業(yè)指導(dǎo)書12Note注釋Toassurewarrantyoffitnessforbestmoldfunctionandbestpartquality:為確保最佳的模具功能和最佳的產(chǎn)品質(zhì)量的合理的依據(jù)Allcleaning,serviceormaintenanceintervalshavetobedocumentedbyresponsibleperson!所有的清潔，維修與內(nèi)部保養(yǎng)，責(zé)任人須將其文件化Nobodycanexpectahighlypartqualityifthemoldisdirty,wornout,wrongadjusted,badlymounted,notproperlycooled,moldingparametersarenotadjustedaccordingtomaterialdatasheetorotherrelateddevicesarenotworkingproperly.如果模具臟污，破損，錯誤的調(diào)整，安裝不好，不正確的冷卻，工藝參數(shù)不是按按照材料的性能數(shù)據(jù)表設(shè)定，或其它的輔助設(shè)備工作不正常，就不可能得到合格的注塑產(chǎn)品。Anyrecommendationforguidelineimprovementormissingitemswithinthisdocumentarewelcome!對本指南尚需改進(jìn)的地方或疏漏之處，歡迎提出寶貴建議！SafetyGuideline安全方針Beforeproceedingpleasereadthedetailsofthisguidelinecarefullytoavoidmoldormachinedamageoraccidentsbymishandlingthemoldorequipmentorthemachinecontrolorthemoldingmachineitself!為避免錯誤的操作機(jī)器或設(shè)備，或模具，或機(jī)器控制系統(tǒng)，導(dǎo)致模具或機(jī)器的損壞或事故，請?jiān)谶M(jìn)行操作之前仔細(xì)的閱讀本指南。Beforeoperatingthemoldor/andcontrolsystemaspecialistshouldcheckallelectricalconnections.Itshouldmatchlocalrequirementsorguidelinesfromyourcompany(e.g.hotrunnerconnection!)。在操作模具或機(jī)器控制系統(tǒng)前，必須由專業(yè)人員檢查電器的連接，機(jī)器或模具必須與工廠內(nèi)的要求或指導(dǎo)方針相一致(比如熱流道的接線方式)Neverbypassanelectricalfuse.任何情況下，不能對保險(xiǎn)絲連接旁路。Avoidanywatercontactofanyelectricalconnectorordevice!避免水接觸到電子連接處或設(shè)備Incaseofwatercontactitisnecessarytodryallpartscarefullybeforeputtingintooperationagain!萬一水接觸到電子元器件，在運(yùn)轉(zhuǎn)之前，首先將濕的零件擦拭干燥好。1.5?Afteranyinterruptionorbreakofmoldingprocessthemoldshouldheated-upsmoothlywithreducedtemperaturetogetallheatersdriedofexistingcondensationwaterfsoftdryingprocess.生產(chǎn)中斷后，應(yīng)該慢慢升高模溫，以用來除去冷凝水。1.6?Incountrieswithhighairhumiditylevel,theheating-upprocesshastobedonewithdelayedtemperatureincreaseeverytimebeforestartrunningfthisistoassureadrysystemandtoremoveexistingcondensationwaterfromthesystem..在高濕度的地區(qū)，在開始之前應(yīng)使用延遲加熱，這是為了確保一個干燥系統(tǒng)和除去系統(tǒng)中存在的冷凝水

Allscrewconnectionshavetobecheckedbeforeoperating(moldplate,ejectorunit,inserts,pressureplates,etc.).運(yùn)轉(zhuǎn)前，必須檢查所有的連接的螺絲(如模板，射座，型芯上的)Aftereveryinterruptionorbreakofproductioncheckthemoldmovementareasandassurethatthesliderareattherightposition.每次生產(chǎn)中斷后，須檢查模具動作的區(qū)域，確?；瑝K在正確的位置Beforedemountingthemoldallsafetypartshavetobeassembled,i.e.ejectorplatelockormoldprotectionlock.在下模之前，所有的安全部件必須裝上，如頂板鎖定塊，模具保護(hù)塊等。Weeklycheckofallcooling/heatinghoses.Exchangebrittlepipes/hoses!每周檢查冷卻/加熱的軟管，更換變脆的軟管。Weeklyallcouplingsofthehoseshavetobecheckedforpropersafetyfunction.每周檢查管路的快速街頭是否脫落，確保操作者安全。Dailychecktheejectorcouplerfortightfit.每日檢查頂桿連接處的固定情況Dailychecktheejectorstrokeforcorrectadjustment.每日檢查頂桿的頂出位置并正確調(diào)整Usethesetupforthemoldprotectioninthisway,thatthereisnopossibilitytodamagethemolddueforeignsubstanceormechanicalreason.Theclampingforceshouldtocomeineffectwhenthemoldplatesareincontact.使用準(zhǔn)備模式，可以對模具進(jìn)行保護(hù)，防止因不相關(guān)的物質(zhì)或機(jī)械原因，導(dǎo)致對模具的損壞，此時(shí)只有在兩模板接觸到時(shí)才會產(chǎn)生鎖模力。Neverinjectintoanopenmoldwithoutpurposeoradditionalprotectionofmoldinserts.在模具打開且型芯沒有外加防護(hù)的情況下，禁止向模具內(nèi)射料。Pleasewearsuitableglovesforcleaningorrepairingthemoldtoavoidinjury.為避免傷害，在清潔或修理模具時(shí)請戴上手套。Byoperatingwithhotelementsorhot-runnerelementseverytimesuitablesafetyglovesmustbeworn.每次操作熱的元器件或熱流道器件，必須戴上合適的安全手套Switchoffthevoltagetogetnoriskofmanipulationduringalongturninterruption.在機(jī)器長期停止期間關(guān)閉電源，以防止給操作者帶來危險(xiǎn)。Neverstartrunningwhenthesafetyguardgateisopenandneverdisassembleanysafetyswitchorsafetyequipment!1.7.1.81.91.101.111.121.131.141.151.161.171.181.19禁止在安全門打開時(shí)開始操作機(jī)器，禁止拆卸任何安全開關(guān)或安全設(shè)備。MoldSet-UpProcess上模程序Togeta100percentparallelismcleanthemachineplateandthemoldplatewithacloth,sothattheyarefreeofrust,chippingetc.為獲得100%的平行度，須用抹布清潔機(jī)器模板和模具模板上的銹，碎片等。Fixthemoldtothemachineplateontheinjectionsidewithacenteringring,screwitandclosethemovingmachineplateinsetupmodus(reduceclampingpressure/force;reducehydraulicpressure).Insomecases(handlingsystemorverticalinjectionunit)adjustthemoldwithawaterlevel.使用定位把模具安裝在射出側(cè)，用螺絲定位后，在準(zhǔn)備狀態(tài)下(為減小鎖模力/壓力，液壓壓力)，合上模板，調(diào)整模具水平。Calibratethemoldheight(setupmodus).在準(zhǔn)備狀態(tài)下，調(diào)模厚Screwthemoldplatewiththemovingmachineplate.用螺絲把模具動模側(cè)固定好Openthemold(setupmodus).在準(zhǔn)備模式下開模Coupleandthanadjusttheejector(setupmodus).Avoidthattheejectorgoesblocktootheoppositeplate.Ensurethattheejectorisatthebackposition.在準(zhǔn)備狀態(tài)下連接并調(diào)整頂桿，避免頂桿卡死。確保能回到正確的位置Connectwater,airandelectricity.連接水，氣和電路Assureallconnectionsareinstalledproperly.Checkwithairwhetherallcyclesareconnected.確保所有的連接安裝正確，使用氣槍檢查是否所有的回路都被連接Assurewaterhosesarenottoolongortooshort,sothatthereisnooverbendingorrubbingagainstanysharpedgeorobstacle.確認(rèn)水管不是太長或太短，避免彎曲太大或與尖的邊緣或障礙物摩擦Switchonthecoolingsystem(controller)andcheckthatnohoseorcouplerisleaky.打開冷卻水開關(guān)，檢查水管與接頭無漏水Checkthatthereisnoleakyspotinthemold(cavities,moldplates,sliders).檢查模具型腔，模板，滑塊是否漏水Note:Anyleakyspotcandamagethesteelduetoburningwaterspotonsteelsurface!注：任何漏點(diǎn)都可能因鋼材表面的氣化水點(diǎn)導(dǎo)致?lián)p壞鋼材Adjusttherightstrokeandvelocityforthemold.Forfirstsetupandfirstmoldclosingmovementreducetheclosingspeedtoaminimumtoavoidanddamage(setupmodus)!Forproductionalsoadjusttheclosingmovementtoalowerspeedwhenguidepinsandangularpinsstarttoproceed.正確調(diào)整模具的位置與速度，第一次模具架模與第一次模具閉合，在準(zhǔn)備模式下，降低至最小速度以避免損壞模具。在生產(chǎn)時(shí)，當(dāng)導(dǎo)柱或有尖角的型芯接觸時(shí)，也須調(diào)整鎖模速度慢一些Note:Guidepinsshouldbeslightlygreased,andneverrundry!注：導(dǎo)柱必須涂上適量潤滑油脂，禁止無潤滑油脂運(yùn)轉(zhuǎn)Closeandopenthemoldafewtimesandcheckwhetherthemovementiscorrect(setupmodus).在準(zhǔn)備模式下，開合模幾次，檢查動作是否正常Switchonthehotrunneraccording3.5.依照3.5章，打開熱流道Themoldhastobeclosedduringheatingprocess.在加熱過程中，模具應(yīng)處于合模狀態(tài)Whenthemoldreachestherequiredtemperatureopenandclosethemoldagain(setupmodus)andrecheckthemoldheight,thanaddtheclampingforce(manualmodus).當(dāng)溫度至設(shè)定的溫度時(shí)，再次在準(zhǔn)備模式下開合模，再次確認(rèn)模厚，在手動模式下加上鎖模力Onlyusewaterwhichisneutral(PH-value7.1-7.5),toachievewaterrequirementsthewaterhastobetreated.使用的水必須是符合水質(zhì)要求，經(jīng)過處理的中性水(PH值在7.1-7.5間)Cleancavities,slidersandpartingplanesothattheyarefreefromrust,shadows,filmlayerorothersubstances.Usesuitablerubbertocleanallvisiblesurfacesonaregularbase.清潔型腔，滑塊和分型面以防止模具生銹，產(chǎn)生暗影，形成塑料薄層等。用專用的橡膠筆定期清理模具表面。Adjustapropermoldprotectionandrecheckthesettingstoavoidanymolddamage.正確調(diào)整模具的保護(hù)，重新檢查設(shè)定，避免任何的模具的損壞Heating-upProcess加熱程序Moldhastobeclosedwithoutclampingforce(setupmodus).在準(zhǔn)備模式下，合上模具，處于無鎖模力的狀態(tài)Switchonthetemperature/coolingcontrolsystem.Assureallsystemsaresealed.打開模溫控制系統(tǒng)，確保系統(tǒng)密封良好Switchontemperaturecontroller.打開溫度控制器Switchonthehotrunnersystemwithdelayedheating-upcurve.使用延遲加熱方式打開熱流道系統(tǒng)，F(xiàn)irstlythehotrunnertemperatureshouldbeadjustedtoabout100degreeforapprox.10minutes.Thisistoassurethatapotentialhumiditylayer(condensationwater)isevaporatedbeforeheating-uptomaximumtemperature.首先調(diào)整熱流道溫度到100攝氏度，保持10分鐘，目的是為了保證潛在的水層(凝結(jié)水)在加熱至最高溫度前蒸發(fā)掉。Duringtheheating-upprocesscheckthefunctionofthehotrunnerbyusingthecontrolsystem(e.g.checkcurrentvalueforeachnozzle).Hereyoucancheckalreadywhetherthehotrunnerisproperlyworkingandinrangeoftoleranceforeachheatingzone.在加熱過程中，首先檢查熱流道的功能(如每個噴嘴的實(shí)際值)直到熱流道正確工作且每個加熱區(qū)在公差范圍內(nèi)。Checkmaterialdatasheetforcorrecttemperatureadjustment..依材料物性表調(diào)整溫度Whentheprocesstemperatures(mold,hotrunner)arereachedadjustthemoldheight(setupmodus),thenswitchovertomanualmodustoset-uptheclampingforce.當(dāng)制程溫度(模具，熱流道)到達(dá)后，在準(zhǔn)備狀態(tài)下調(diào)整模厚，然后切換至手動模式，設(shè)定鎖模力Recheckthemoldprotection(bypressureandtime).再次檢查模具保護(hù)設(shè)定(壓力和時(shí)間)Start-upProcess開始程序Startthemoldingprocesswhenallprocesstemperaturesarereached.(mold,hotrunner,nozzle,barrel).在所有的溫度(模具，熱流道)到達(dá)后開始注塑制程Beforetheinjectionprocessisgoingtostart,spoutfewtimestheaggregate.Thisistoassurebestpossibleinprocessmaterialcondition.在注塑之前，空射幾次，目的是為了確保最好的材料狀況Themachinenozzlehastofitthemoldbushcorrectly(checkthepositionortouch-upwithapieceofpaper).However,thismayvaryfromdifferentnozzlefittingsystems.機(jī)器的噴嘴必須與模具澆口套相配合良好(使用一張紙檢查位置與接觸狀況)Forfirstsamplingalwaysstartwithafillingstudy.Takecarethatnocavityisoverloaded.Startwithasmoothadjustment.Storethefillingstudyparts.經(jīng)常在第一次試模時(shí)進(jìn)行充填分析，注意不可過度充填，開始時(shí)進(jìn)行微調(diào)。保留充填分析的樣品Accordingtothefillingstudyresulttrytobalancethehotrunnernozzlesforeachcavity.根據(jù)充填分析結(jié)果，對每個熱流道進(jìn)行調(diào)節(jié)以達(dá)到平衡Afterapprox.98percentfillgradeswitchovertoholdingpressure.大約充填至98%時(shí)，轉(zhuǎn)換為保壓階段Holdingpressuretimedependsofgateandpartdesign;Takeweightoftheplasticpartswithoutspruetogetthecorrectholdingpressuretime.保壓時(shí)間取決于澆口與產(chǎn)品的設(shè)計(jì)，通過稱量產(chǎn)品的凈重以獲得合適的保壓時(shí)間Note:Ifgateisfrozen,noholdingpressurewillbeactiveinthepartandpartweightcannotbeincreasedanymore!注：如果澆口已冷卻，保壓不會再對產(chǎn)品產(chǎn)生效果，產(chǎn)品的重量不會再增加Choosetheproperadjustmentofinjectionvelocitytofillthecavities,dependingofpartdesign,partthickness,moldtemperature,surfacequalityetc.依據(jù)產(chǎn)品設(shè)計(jì)，壁厚，模溫和產(chǎn)品的表面質(zhì)量，選擇合適的充填速度。Choosethepropercoolingtimetoachievebestpossible(necessary)partquality.選取合適的冷卻時(shí)間以獲得最優(yōu)的產(chǎn)品品質(zhì)Checkthepartquality(surface,sinkmarks,jointlines,shrinkage,warpage,etc.)檢查產(chǎn)品的質(zhì)量(表面外觀，縮水，結(jié)合線，收縮，翹曲等)Payattentionthatthesprueandplasticpartsareeasytoreleaseduringejectionstroke.注意產(chǎn)品在頂出過程中，料桿與產(chǎn)品是否容易脫模Incasestherearestickingplasticpartsatthecoreonlyusecooperorbrasstoforcethesparts.萬一有產(chǎn)品粘在型芯上，只能用紫銅或黃銅工具去除Duringproduction生產(chǎn)過程Theejectorplateshouldnotgoblock.頂針板不可被卡死Avoidthatthereisjammedplasticmaterialinanymoldarea.避免在模具的任何地方存在壓碎的塑料原料

5.35.466.16.26.36.477.17.1.17.1.27.1.37.1.47.1.57.1.77.1.87.1.97.27.2.17.2.2Choosetheinjectionpressureandtimetoavoidoverstressinthemold.選擇合適的射出壓力與時(shí)間，以避免過度充填Checkthecoolingwatertemperatureandtheflowrate.檢查冷卻水的溫度與流速Colour/materialchange換色與換料Stopthematerialsupply.停止原料供應(yīng)Produceuntilthescrewdoesn'trpelascthifictahteionstroke.繼續(xù)生產(chǎn)直至螺桿無法達(dá)到計(jì)量位置Cleanthehopper,thenozzleandthefeedbush清洗原料儲料筒，噴嘴和澆口套Spoutaggregateuntiltheextrusionmaterialisclean/regular射料直至射出的料已干凈/正常Maintenance保養(yǎng)General概要Checkallscrewsofinjectionmold.檢查模具上的所有的螺絲Checkwhethertheejectorunitisloose.檢查頂出桿是否松動Inspectcouplings,waterhoseandhydraulichosewhethertheyareleaky.檢查接頭的連接，水管各液壓管路是否泄漏Checkcontrolsystems,i.e.hotrunnersystem,coolingsystem.檢查控制系統(tǒng)，如熱流道，冷卻系統(tǒng)Checkmoldprotectionadjustment(timeandpressure).檢查模具保護(hù)的時(shí)間與壓力Inspectregularallmachineparameters,i.e.backflowblockade,pv-regulator;takecareforit.定期檢查機(jī)器的參數(shù)，如止逆閥，Checkairsystemforleackage.檢查氣路是否泄漏Takecarethattherearenoforeignpartsorplasticpartsbetweenthepartingareasorbetweensliders,ejectorplate,etc.檢查產(chǎn)品成型型芯，滑塊間，頂板間，沒有其它無關(guān)的物品或料料產(chǎn)品Shiftchange日保養(yǎng)Cleanworkingarea.清潔工作區(qū)域Cleancavitiesandpartingsurfaces.清潔型芯和分型面

Comparemoldingdatasheetwithsetup.Incaseofsomedeviationspleasemakedocumentation.比較設(shè)定值與實(shí)際值，如果有不同的沖突的地方，進(jìn)行文件更改7.3Weekly周保養(yǎng)Cleanguidingelementsandrenewifnecessaryalllubrications.清潔導(dǎo)向部件，必要時(shí)更換潤滑油Disassembleandcleanslider,coreandstripperplate.卸下滑塊，型芯和頂出板并清潔Inspectthecoolingsystem,checkthewaterflowrate/pressure.檢查冷卻系統(tǒng)，檢查水壓及流量Checkthewaterquality,PH-value.檢查水質(zhì)，PH值Checkallscrewsinthemold.檢查模具上的所有的螺絲Cleanthefeedbushandthenozzleoftheinjectionunit.清潔澆口套，噴嘴Howtocleanthemold如何清潔模具Useclothandethylalcohol(spirit).使用抹布和乙醇(酒精)Clothshouldbemadeofcotton.必須是棉布Ifitisnotfeasibletocleanwithaclothusepolishpaste,becarefulanduseonlyafinepaste(donotpracticeonEDMsurfaces).如果在拋光面上無法使用抹布，則只能使用研磨膏，仔細(xì)的使用細(xì)的研磨膏。(不要在放電面上使用)TocleantheEDMsurfacefromfilm/disposaluseonlyspiritor/andsuitablerubberpen.清除放電面上的塑料薄層，只能使用皮紋清洗膏(涂皮紋清洗膏于需清理處，使用軟毛刷輕輕地刷除)或合適的橡皮筆清除。Takingoutofservice下模保養(yǎng)Forshortterm短期保養(yǎng)Switchoffhotrunnersystem.關(guān)掉熱流道系統(tǒng)Spouttheinjectionunit.射空料管中的料Formaterialswitchover(type)usecleaner(PP)tocleantheaggregate.如更換材料類型，使用PP料清潔。Switchofftheinjectionunit.關(guān)閉射出單元Switchoffthecoolingcontrollerforthemovingplate.Fortemperaturesatabout/over70/80Ccooldown(controllerfunction).關(guān)閉動模的冷卻系統(tǒng)，如果模溫在70/80攝氏度的，要啟動冷卻功能按鈕。Thecoolingsystematthestationaryplate(wherethehotrunnerisconnected)shouldrununtiltheplatetemperatureislessthan100degreeCelsius.Switchoff.定模板的冷卻系統(tǒng)(熱流道安裝處)須在溫度降至100度以下時(shí)方可關(guān)閉。Useexhaustfunctionbycoolingcontrollerswhereitisavailable.用模溫機(jī)的倒吸功能現(xiàn)將模具中的水排回。Blowthewateroutofthecoolingpipes(airpistol).使用氣槍吹干水管Beforedemountthemoldithastocleancareful.下模之前仔細(xì)清理模具Userustinhibitortoprotectthemold,especiallythecavities.使用除銹劑保護(hù)模具，尤其是型腔Forlongterm(>3month)長期保養(yǎng)Ifthemoldgoesoutofserviceformorethanfewweeksitistodisassemble,toclean(spirit,polishpaste,etc.)andtospray(rustinhibitor)carefully.Especialcleanthecavities,partingplane,etc.如果模具超過幾周沒有保養(yǎng)，清理模具(必要時(shí)拋光)，仔細(xì)噴防銹劑，尤其是型芯，分型面Guideelementsormovingpartshavetobegreased.導(dǎo)向部件或移動部件須涂上潤滑油Electricalplugshavetobecovered.電插頭必須蓋住Coolingconnectionshavetobecoveredwithplasticnipples.冷卻水接頭須用塑料封住Malfunction故障9.1Incaseonecavityblocked堵穴情況Checktheheat.檢查加熱Checkthegate.Disassemblethegateinsert(hotrunner)andgiveavisualcheck.Cleanit.Reassemblebuttakecarefortheseals.檢查澆口，卸下澆口型芯(熱流道)，目視檢查，清洗，重新組裝，注意密封狀況Whenthereisakindofforeignsubstancekeepit,analyseitanddocumentit.當(dāng)有異常的物質(zhì)存在時(shí)，分析并在文件中記錄Emptythehopperandcheckthematerial.清空儲料筒并檢查原料Spouttheinjectionunitfewtimes.-空射料筒中的原料幾次Spoutthehotrunnerbeforeyoureassemblethegateinsert.Becareful,useonlythefunctionplasticizes,sothereisalowpressure.Neverusethefunctioninjectionwhenthegateisdisassembled.拆卸熱流道澆口處型芯前，首先要射空熱流道里的料。注意，只能用塑化功能來擠出(此時(shí)壓力低)，千萬不能在澆口拆下狀態(tài)后射料。Lossrangeoftolerancebyplasticparts產(chǎn)品超出公差范圍Checktheinjectionprocesssetup(temperatures,times,velocities,pressures,etc.)檢查工藝設(shè)定(溫度，時(shí)間，速度，壓力等)Checkcoolingsystem檢查冷卻系統(tǒng)Getanoisyscrew(injectionunit)螺桿噪音Assurethatthecylinderheathavethepropertemperature確認(rèn)加熱溫度正常Assurethatthetraversetemperatureisnottoohigh確認(rèn)下料口溫度不是太高Observetheplasticizespeed觀察塑化速度Doublecheckmaterialresignsforanypollutionandforeignmaterial再次檢查原料粒子是否被污染或混入其它原料Checkthesizeofregranulate/repellits檢查回料顆粒的尺寸Disassemblethescrewandcheckforanydefectandscratches.拆螺桿檢查是否有劃傷和其它缺陷Blackdots黑點(diǎn)Cleancompleteinjectionunit.清潔注塑單元Assurethatthehotrunnertemperature