寶潔公司注塑成型車間培訓(xùn)資料

寶潔公司注塑成型車間培訓(xùn)資料寶潔公司注塑成型車間培訓(xùn)資料寶潔公司注塑成型車間培訓(xùn)資料OperatingandPreventiveMaintenanceGuidelineforHighPerformanceInjectionMolding高效注射成型的操作與預(yù)防保養(yǎng)指南Note 31 SafetyGuideline安全方針 32 MoldSet-UpProcess模具上模程序 53 Heating-upProcess加熱程序 64 Start-upProcess開始程序 75 Duringproduction生產(chǎn)過程 86 Colour/materialchange換色/換料 87 Maintenance保養(yǎng) 87.1 General概要 87.2 Shiftchange日保養(yǎng) 97.3 Weekly周保養(yǎng) 97.4 Howtocleanthemold如何清潔模具 98 Takingoutofservice下模保養(yǎng) 108.1 Forshortterm短期 108.2 Forlongterm(>3month)長期（>3個月） 109 Malfunction故障 119.1 Incaseonecavityblocked萬一有一穴堵住 119.2 Lossrangeoftolerancebyplasticparts產(chǎn)品偏離公差范圍 119.3 Getanoisyscrew(injectionunit)螺桿有噪音（射出單元） 119.4 Blackdots黑點 119.5 Deviationofpartwallthickness產(chǎn)品壁厚偏差 1210 GeneralInstruction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!對本指南尚需改進的地方或疏漏之處，歡迎提出寶貴建議！1 SafetyGuideline安全方針Beforeproceedingpleasereadthedetailsofthisguidelinecarefullytoavoidmoldormachinedamageoraccidentsbymishandlingthemoldorequipmentorthemachinecontrolorthemoldingmachineitself!為避免錯誤的操作機器或設(shè)備，或模具，或機器控制系統(tǒng)，導(dǎo)致模具或機器的損壞或事故，請在進行操作之前仔細的閱讀本指南。1.1 Beforeoperatingthemoldor/andcontrolsystemaspecialistshouldcheckallelectricalconnections.Itshouldmatchlocalrequirementsorguidelinesfromyourcompany(e.g.hotrunnerconnection!)。在操作模具或機器控制系統(tǒng)前，必須由專業(yè)人員檢查電器的連接，機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）1.2 Neverbypassanelectricalfuse.任何情況下，不能對保險絲連接旁路。1.3 Avoidanywatercontactofanyelectricalconnectorordevice!避免水接觸到電子連接處或設(shè)備1.4 Incaseofwatercontactitisnecessarytodryallpartscarefullybeforeputtingintooperationagain!萬一水接觸到電子元器件，在運轉(zhuǎn)之前，首先將濕的零件擦拭干燥好。1.5? Afteranyinterruptionorbreakofmoldingprocessthemoldshouldheated-upsmoothlywithreducedtemperaturetogetallheatersdriedofexistingcondensationwater→softdryingprocess.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-upprocesshastobedonewithdelayedtemperatureincreaseeverytimebeforestartrunning→thisistoassureadrysystemandtoremoveexistingcondensationwaterfromthesystem..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1.7. Allscrewconnectionshavetobecheckedbeforeoperating(moldplate,ejectorunit,inserts,pressureplates,etc.).運轉(zhuǎn)前，必須檢查所有的連接的螺絲（如模板，射座，型芯上的）1.8 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1.9 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，模具保護塊等。1.10 Weeklycheckofallcooling/heatinghoses.Exchangebrittlepipes/hoses!每周檢查冷卻/加熱的軟管，更換變脆的軟管。1.11 Weeklyallcouplingsofthehoseshavetobecheckedforpropersafetyfunction.每周檢查管路的快速街頭是否脫落，確保操作者安全。1.12 Dailychecktheejectorcouplerfortightfit.每日檢查頂桿連接處的固定情況1.13 Dailychecktheejectorstrokeforcorrectadjustment.每日檢查頂桿的頂出位置并正確調(diào)整1.14 Usethesetupforthemoldprotectioninthisway,thatthereisnopossibilitytodamagethemolddueforeignsubstanceormechanicalreason.Theclampingforceshouldtocomeineffectwhenthemoldplatesareincontact.使用準備模式，可以對模具進行保護，防止因不相關(guān)的物質(zhì)或機械原因，導(dǎo)致對模具的損壞，此時只有在兩模板接觸到時才會產(chǎn)生鎖模力。1.15 Neverinjectintoanopenmoldwithoutpurposeoradditionalprotectionofmoldinserts.在模具打開且型芯沒有外加防護的情況下，禁止向模具內(nèi)射料。1.16 Pleasewearsuitableglovesforcleaningorrepairingthemoldtoavoidinjury.為避免傷害，在清潔或修理模具時請戴上手套。1.17 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1.18 Switchoffthevoltagetogetnoriskofmanipulationduringalongturninterruption.在機器長期停止期間關(guān)閉電源，以防止給操作者帶來危險。1.19 Neverstartrunningwhenthesafetyguardgateisopenandneverdisassembleanysafetyswitchorsafetyequipment!禁止在安全門打開時開始操作機器，禁止拆卸任何安全開關(guān)或安全設(shè)備。2 MoldSet-UpProcess上模程序2.1 Togeta100percentparallelismcleanthemachineplateandthemoldplatewithacloth,sothattheyarefreeofrust,chippingetc.為獲得100%的平行度，須用抹布清潔機器模板和模具模板上的銹，碎片等。2.2 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。2.3 Calibratethemoldheight(setupmodus).在準備狀態(tài)下，調(diào)模厚2.4 Screwthemoldplatewiththemovingmachineplate.用螺絲把模具動模側(cè)固定好2.5 Openthemold(setupmodus).在準備模式下開模2.6 Coupleandthanadjusttheejector(setupmodus).Avoidthattheejectorgoesblocktootheoppositeplate.Ensurethattheejectorisatthebackposition.在準備狀態(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2.7 Connectwater,airandelectricity.連接水，氣和電路2.8 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2.9 Assurewaterhosesarenottoolongortooshort,sothatthereisnooverbendingorrubbingagainstanysharpedgeorobstacle.確認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2.10 Switchonthecoolingsystem(controller)andcheckthatnohoseorcouplerisleaky.打開冷卻水開關(guān)，檢查水管與接頭無漏水2.11 Checkthatthereisnoleakyspotinthemold(cavities,moldplates,sliders). 檢查模具型腔，模板，滑塊是否漏水Note:Anyleakyspotcandamagethesteelduetoburningwaterspotonsteelsurface!注：任何漏點都可能因鋼材表面的氣化水點導(dǎo)致?lián)p壞鋼材2.12 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，在準備模式下，降低至最小速度以避免損壞模具。在生產(chǎn)時，當導(dǎo)柱或有尖角的型芯接觸時，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，禁止無潤滑油脂運轉(zhuǎn)2.13 Closeandopenthemoldafewtimesandcheckwhetherthemovementiscorrect(setupmodus).在準備模式下，開合模幾次，檢查動作是否正常2.14 Switchonthehotrunneraccording3.5.依照3.5章，打開熱流道2.15 Themoldhastobeclosedduringheatingprocess.在加熱過程中，模具應(yīng)處于合模狀態(tài)2.16 Whenthemoldreachestherequiredtemperatureopenandclosethemoldagain(setupmodus)andrecheckthemoldheight,thanaddtheclampingforce(manualmodus).當溫度至設(shè)定的溫度時，再次在準備模式下開合模，再次確認模厚，在手動模式下加上鎖模力2.17 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）2.18 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。2.19 Adjustapropermoldprotectionandrecheckthesettingstoavoidanymolddamage.正確調(diào)整模具的保護，重新檢查設(shè)定，避免任何的模具的損壞3 Heating-upProcess加熱程序3.1 Moldhastobeclosedwithoutclampingforce(setupmodus).在準備模式下，合上模具，處于無鎖模力的狀態(tài)3.2 Switchonthetemperature/coolingcontrolsystem. Assureallsystemsaresealed.打開模溫控制系統(tǒng)，確保系統(tǒng)密封良好3.3 Switchontemperaturecontroller. 打開溫度控制器3.4 Switchonthehotrunnersystemwithdelayedheating-upcurve.使用延遲加熱方式打開熱流道系統(tǒng)，3.5 Firstlythehotrunnertemperatureshouldbeadjustedtoabout100degreeforapprox.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。3.6 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)。3.7 Checkmaterialdatasheetforcorrecttemperatureadjustment..依材料物性表調(diào)整溫度3.8 Whentheprocesstemperatures(mold,hotrunner)arereachedadjustthemoldheight(setupmodus),thenswitchovertomanualmodustoset-uptheclampingforce.當制程溫度（模具，熱流道）到達后，在準備狀態(tài)下調(diào)整模厚，然后切換至手動模式，設(shè)定鎖模力3.9 Recheckthemoldprotection(bypressureandtime).再次檢查模具保護設(shè)定（壓力和時間）4 Start-upProcess開始程序4.1 Startthemoldingprocesswhenallprocesstemperaturesarereached. (mold,hotrunner,nozzle,barrel).在所有的溫度（模具，熱流道）到達后開始注塑制程4.2 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4.3 Themachinenozzlehastofitthemoldbushcorrectly(checkthepositionortouch-upwithapieceofpaper).However,thismayvaryfromdifferentnozzlefittingsystems.機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）4.4 Forfirstsamplingalwaysstartwithafillingstudy.Takecarethatnocavityisoverloaded.Startwithasmoothadjustment.Storethefillingstudyparts.經(jīng)常在第一次試模時進行充填分析，注意不可過度充填，開始時進行微調(diào)。保留充填分析的樣品4.5 Accordingtothefillingstudyresulttrytobalancethehotrunnernozzlesforeachcavity.根據(jù)充填分析結(jié)果，對每個熱流道進行調(diào)節(jié)以達到平衡4.6 Afterapprox.98percentfillgradeswitchovertoholdingpressure.大約充填至98%時，轉(zhuǎn)換為保壓階段4.7 Holdingpressuretimedependsofgateandpartdesign;Takeweightoftheplasticpartswithoutspruetogetthecorrectholdingpressuretime.保壓時間取決于澆口與產(chǎn)品的設(shè)計，通過稱量產(chǎn)品的凈重以獲得合適的保壓時間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4.8 Choosetheproperadjustmentofinjectionvelocitytofillthecavities,dependingofpartdesign,partthickness,moldtemperature,surfacequalityetc.依據(jù)產(chǎn)品設(shè)計，壁厚，模溫和產(chǎn)品的表面質(zhì)量，選擇合適的充填速度。4.9 Choosethepropercoolingtimetoachievebestpossible(necessary)partquality.選取合適的冷卻時間以獲得最優(yōu)的產(chǎn)品品質(zhì)4.10 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）4.11 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5 Duringproduction生產(chǎn)過程5.1 Theejectorplateshouldnotgoblock.頂針板不可被卡死5.2 Avoidthatthereisjammedplasticmaterialinanymoldarea.避免在模具的任何地方存在壓碎的塑料原料5.3 Choosetheinjectionpressureandtimetoavoidoverstressinthemold.選擇合適的射出壓力與時間，以避免過度充填Checkthecoolingwatertemperatureandtheflowrate.檢查冷卻水的溫度與流速6 Colour/materialchange換色與換料6.1 Stopthematerialsupply.停止原料供應(yīng)6.2 Produceuntilthescrewdoesn’treachtheplastificationstroke.繼續(xù)生產(chǎn)直至螺桿無法達到計量位置6.3 Cleanthehopper,thenozzleandthefeedbush清洗原料儲料筒，噴嘴和澆口套6.4 Spoutaggregateuntiltheextrusionmaterialisclean/regular射料直至射出的料已干凈/正常7 Maintenance保養(yǎng)7.1 General概要7.1.1 Checkallscrewsofinjectionmold.檢查模具上的所有的螺絲7.1.2 Checkwhethertheejectorunitisloose.檢查頂出桿是否松動7.1.3 Inspectcouplings,waterhoseandhydraulichosewhethertheyareleaky.檢查接頭的連接，水管各液壓管路是否泄漏7.1.4 Checkcontrolsystems,i.e.hotrunnersystem,coolingsystem.檢查控制系統(tǒng)，如熱流道，冷卻系統(tǒng)7.1.5 Checkmoldprotectionadjustment(timeandpressure).檢查模具保護的時間與壓力7.1.7 Inspectregularallmachineparameters,i.e.backflowblockade,pv-regulator;takecareforit.定期檢查機器的參數(shù)，如止逆閥，7.1.8 Checkairsystemforleackage.檢查氣路是否泄漏7.1.9 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7.2 Shiftchange日保養(yǎng)7.2.1 Cleanworkingarea.清潔工作區(qū)域7.2.2 Cleancavitiesandpartingsurfaces.清潔型芯和分型面7.2.3 Comparemoldingdatasheetwithsetup.Incaseofsomedeviationspleasemakedocumentation.比較設(shè)定值與實際值，如果有不同的沖突的地方，進行文件更改7.3 Weekly周保養(yǎng)7.3.1 Cleanguidingelementsandrenewifnecessaryalllubrications.清潔導(dǎo)向部件，必要時更換潤滑油7.3.2 Disassembleandcleanslider,coreandstripperplate.卸下滑塊，型芯和頂出板并清潔7.3.3 Inspectthecoolingsystem,checkthewaterflowrate/pressure.檢查冷卻系統(tǒng)，檢查水壓與流量7.3.4 Checkthewaterquality,PH-value.檢查水質(zhì)，PH值7.3.5 Checkallscrewsinthemold.檢查模具上的所有的螺絲7.3.6 Cleanthefeedbushandthenozzleoftheinjectionunit.清潔澆口套，噴嘴7.4 Howtocleanthemold如何清潔模具7.4.1 Useclothandethylalcohol(spirit).使用抹布和乙醇（酒精）7.4.2 Clothshouldbemadeofcotton.必須是棉布7.4.3 Ifitisnotfeasibletocleanwithaclothusepolishpaste,becarefulanduseonlyafinepaste(donotpracticeonEDMsurfaces).如果在拋光面上無法使用抹布，則只能使用研磨膏，仔細的使用細的研磨膏。（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。8 Takingoutofservice下模保養(yǎng)8.1 Forshortterm短期保養(yǎng)8.1.1 Switchoffhotrunnersystem.關(guān)掉熱流道系統(tǒng)8.1.2 Spouttheinjectionunit.射空料管中的料8.1.3 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8.1.5 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。8.1.6 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度以下時方可關(guān)閉。8.1.7 Useexhaustfunctionbycoolingcontrollerswhereitisavailable.用模溫機的倒吸功能現(xiàn)將模具中的水排回。8.1.8 Blowthewateroutofthecoolingpipes(airpistol).使用氣槍吹干水管8.1.9 Beforedemountthemoldithastocleancareful.下模之前仔細清理模具8.1.10 Userustinhibitortoprotectthemold,especiallythecavities.使用除銹劑保護模具，尤其是型腔8.2 Forlongterm(>3month)長期保養(yǎng)8.2.1 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（必要時拋光），仔細噴防銹劑，尤其是型芯，分型面8.2.2 Guideelementsormovingpartshavetobegreased.導(dǎo)向部件或移動部件須涂上潤滑油8.2.3 Electricalplugshavetobecovered.電插頭必須蓋住8.2.4 Coolingconnectionshavetobecoveredwithplasticnipples.冷卻水接頭須用塑料封住9 Malfunction故障9.1 Incaseonecavityblocked堵穴情況9.1.1 Checktheheat.檢查加熱9.1.1 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9.1.3 Whenthereisakindofforeignsubstancekeepit,analyseitanddocumentit.當有異常的物質(zhì)存在時，分析并在文件中記錄9.1.4 Emptythehopperandcheckthematerial.清空儲料筒并檢查原料9.1.5 Spouttheinjectionunitfewtimes.-空射料筒中的原料幾次9.1.6 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（此時壓力低），千萬不能在澆口拆下狀態(tài)后射料。9.2 Lossrangeoftolerancebyplasticparts產(chǎn)品超出公差范圍9.2.1 Checktheinjectionprocesssetup(temperatures,times,velocities,pressures,etc.)檢查工藝設(shè)定（溫度，時間，速度，壓力等）9.2.2 Checkcoolingsystem檢查冷卻系統(tǒng)9.3 Getanoisyscrew(injectionunit)螺桿噪音9.3.1 Assurethatthecylinderheathavethepropertemperature確認加熱溫度正常9.3.2 Assurethatthetraversetemperatureisnottoohigh確認下料口溫度不是太高9.3.3 Observetheplasticizespeed觀察塑化速度9.3.4 Doublecheckmaterialresignsforanypollutionandforeignmaterial再次檢查原料粒子是否被污染或混入其它原料9.3.5 Checkthesizeofregranulate/repellits檢查回料顆粒的尺寸9.3.6 Disassemblethescrewandcheckforanydefectandscratches.拆螺桿檢查是否有劃傷和其它缺陷9.4 Blackdots黑點9.4.1 Cleancompleteinjectionunit.清潔注塑單元9