PLASTIC CUP FORMING MACHINE

PLASTIC CUP FORMING MACHINE
Detailed descriptionofthewhole machine
1. 放片装置 Sheet setting device
1.1 由气缸提升上料； Lift feeding by cylinder
1.2 适用片材直径 1 米以内； Sheet max. Diameter:≤1000mm
1.3 由超声波传感器来确定预送料的长度， 可检测高透明片材，避免因摆锟对片材表面造成的刮花；
The length of the pre-feed is determined by an ultrasonic sensor, which can detect highly transparent sheets and avoid scratches on the surface of the sheet caused by pendulum.
1.4 送片由电机驱动一对夹送辊， 带送片自动控制。
The feeding is driven by a motor with a pair of clamping rollers, which are automatically controlled by the feeding sheet.
2． 送片装置 Feeding device
2.1 送片装置采用4.4KW 日本安川伺服电机配强珠减速机驱动， 伺服电机总线通讯控制,控制精度在±0.2mm 内；
The film feeding device adopts 4.4KW YASKAWA servo motor and QIANGZHU reducer drive, servo motor bus communication control, control accuracy within ±0.2mm
2.2 链轨材料为特殊钢材硬化处理后拼装组合而成,带通水冷却装置，并配上观测水压压力表,提供供油嘴可对链条导珠进行润滑；
The chain rail material is made of special steel hardening, with water cooling device and equipped with observation water pressure gauge, and an oil supply nozzle can be provided to lubricate the chain guide beads.
2.3 配有 2 段式为自动调整功能， 由于 2 台电机单独调节， 也可以同步调节； 在冷片进入时，自动控制链轨为平行状态， 到一定温度下， 自动张开至喇叭口状态。
Equipped with a 2-stage automatic adjustment function, since the two motors are
adjusted separately, it can also be adjusted synchronously; When the cold plate enters, the automatic control chain rail is in a parallel state, and at a certain temperature, it automatically opens to the flared state.





3． 加热系统 Heating system
3.1 加热区探头瓦片采用爱尔兰CERAMICX 口陶瓷加热片， 其余采用江苏天宝陶瓷加热片 ;
The heating zone probe tiles adopts ceramic heating plate imported from Ireland CERAMICX, and the rest ceramic heating tiles adopts Jiangsu Tianbao；
3.2 电热规格采用： 上下炉 13 区纵向并联， 及上下炉各 10 区横向排布。 一共 33 区。
The electric heating specifications adopt: The 13 zones of the upper and lower electric furnaces are connected in longitudinal parallel, and the each 10 zones of the upper and lower electric furnaces are arranged horizontally. Total 33 zones.
3.3 温度控制系统可以精准的控制温度， 参数设定在触摸屏上设定， 带有断线报警， 可自动判


断某区的加热器的正常工作；
The temperature control system can accurately control the temperature, the parameters are set on the touch screen, with a broken wire alarm, and can automatically judge the normal operation of the heater in a certain area.
3.4 电炉可选配光电检测掉片自动退炉并停机的保护装置；
The electric furnace can be equipped with a protection device for photoelectric detection of chip loss, automatic unloading and shutdown;
3.5 框架采用铝型材、 不锈钢板拼接结构；
The frame adopts aluminum profile and stainless steel plate splicing structure;

(温度控制系统细节图 Detail diagram of the temperature control system)


(温控信号处理模块 Temperature-controlled singal processing module)

(电炉加热瓦细节图 Detail of electric furnace heating tiles)



(铝合金电炉架 Aluminum alloy electric furnace frame)
4. 模内切工位： In mould cutting station
4.1 机架采用国标 120#方管钢钢板组合焊接定型处理而成， 底座焊后再进行龙门加工平面； The frame is made of national standard 120# square pipe steel plate combination welding and shaping treatment, and the base is welded and then the gantry processing plane.
4.2 工位站开合模结构由下固定底座、 下开合模连杆支撑组件， 下开合模动模台、 上固定座、上模具模架及 4 条Φ100mm 立柱组成；
The opening and closing mold structure of the station is composed of the lower fixed base, the lower opening and closing die connecting rod support assembly, the lower opening and closing die moving mold table, the upper fixed seat, the upper opening and closing die connecting rod support assembly, the upper opening and closing die moving mold table, the upper mold base and 4 Φ 100mm columns;
4.3 焊接式底座、动模台、上模台及模架的安装基准面由大型进口数控加工中心一体加工后组装而成， 从而提高设备组装精度， 同时也提高设备生产过程的稳定性；
The installation datum of welding base, moving mold table, upper mold table and die frame is assembled by a large imported CNC machining center after integrated processing, so as to improve the accuracy of equipment assembly and the stability of the equipment production process.
4.4 立柱采用优质钢经调质后表面镀硬铬精磨而成；
The column is made of high quality steel after hard chrome plating and fine grinding on the surface after quenching and tempering.
4.5 动模台由 15KW 日本安川伺服配合美国 GNORD 硬齿面斜锥齿减速机电机驱动曲臂连杆结构进而推动五支点进行开合模， 伺服电机总线通讯控制， 所有连杆采用日本 IKO 轴承传
动与铜合金套， 传动效率高， 减少机械磨损， 便于维护； 动模台开合行程≤250mm；


The moving mold table is driven by 15KW YASKAWA servo with the American GNORD hard tooth surface inclined bevel tooth reducer motor to drive the toggle connecting rod structure and then promote the five fulcrums to open and close the mold, servo motor bus communication control, all connecting rods adopt Japanese IKO bearing transmission and copper alloy sleeve, high transmission efficiency, reduce mechanical wear, easy to maintain; Moving mold table opening and closing stroke≤ 250mm;
4.6 本机上模台调模方式标配为手动锁紧螺母方式
The standard mold adjustment method of the upper mold table of this machine is manual locking nut method.
4.7 成型站配备独立上拉伸装置采用 11KW 日本安川绝对值伺服电机配高速滚珠丝杠驱动， 采用直连式的丝杆螺母结构； 具有拉伸速度快， 定位稳定， 提高产品的均匀及稳定性的优点， 拉伸升降运动行程≤230mm, 制品可向下成型深度≤180mm。
The forming station is equipped with an independent upper stretching device, adopts 11KW YASKAWA absolute servo motor and high-speed ball screw drive, and adopts a direct-connected lead screw nut structure; It has the advantages of fast tensile speed, stable positioning, and improved product uniformity and stability. Stretching lifting stroke is ≤ 230mm, products can be down-forming depth ≤ 180mm.
4.8 成型站配备两款顶杯装置， 分别为气缸顶杯装置与机械式手动可调式顶杯装置。
The forming station is equipped with two types of push-cups-up devices, namely
the cylinder push-cups-up device and the mechanical manual adjustable push-cups-up device.









5. 制品堆叠工位 Product stacking station
5. 1 定制型高速机械手， 自动整理。
Customized high-speed manipulator, automatic sorting.
5.2 机械手传动采用高速伺服电机配台湾利茗高速行星减速机， 轻量化设计
The manipulator transmission adopts high-speed servo motor with Taiwan Liming high-speed planetary reducer, lightweight design.
5.3 机械手程序参数可调， 可客户自编程序周期。
The program parameters of the manipulator are adjustable, and the customer's own program cycle can be programmed.
5.4 机械手整机电机采用日本安川电机系列， 有主机运动控制器整体控制， 实现闭环功能 。 The manipulator motor adopts the YASKAWA motor series, which has the overall control of the host motion controller to achieve the closed-loop function.
5.5 产品自动整理流程： Automated product organization process
5.5.1 产品由两轴平移机械手取出， 放置在一道积料框， 在这个框进行叠杯； 两轴平移机械手由高速低惯量伺服电机驱动；
The product is taken out by a two-axis translation manipulator and placed in a material accumulation box, in which the cup is stacked; The two-axis translation manipulator is driven by a high-speed, low-inertia servo motor.
5.5.2 积料框数量到达后， 该框会自动开闸， 杯子落入一个由伺服电机驱动的转接板上， 转接板会高速行走到垒杯区；
When the number of accumulation boxes is reached, the frame will automatically open and the cup will fall into an adapter plate driven by a servo motor, which will travel at high speed to the cup stacking area.
5.5.3 在垒杯区将整模的杯子整合成一排的形式存在整合框内， 整合方式是在转换板的下方设


置一个往上顶的装置， 这一排整合完成后， 转换板再次高速返回到接杯区等待接杯， 转换板在中间会有个等待区， 当后段出瑞问题时， 积料框的杯子会直接排在输送带上输送出来。 从而不暂停成型机的自动运行；
In the cup stacking area to integrate the whole mold of the cup into a row of the form of the integration frame, the integration method is to set up a device to the top under the conversion plate, after the integration of this row, the conversion plate returns to the cup receiving area again at high speed to wait for the cup, the conversion plate will have a waiting area in the middle, when the problem occurs in the back section, the cup of the accumulation box will be directly discharged on the conveyor belt to transport out. This does not stop the automatic operation of the forming machine.
5.5.4 整合完成一排的杯子由另一套自动翻转架进行抬高后， 翻转至放平后， 再下降至输送带位置； 自动翻转架所有驱动都由总线型的日本安川伺服电机完成；
After the integration of a row of cups, they are raised by another set of automatic flipping frames, flipped to flattened, and then lowered to the conveyor belt position; All drives of the automatic tilting frame are completed by bus-type YASKAWA servo motors.
5.5.5 平齐到输送带后， 由一组长行程气缸， 将整排杯子推至分道形输送带上；
After flushing to the conveyor belt, a set of long-stroke cylinders pushes the entire row of cups onto the divided conveyor belt;
5.5.6 分道形输送带将杯子输送到卷边机或者包装机的流水线上，此分道形输送带上的每道杯子都已经是统一数量， 可以直接配备枕式包装机快速包装；
The aisle conveyor belt conveys the cups to the crimping machine or the assembly line of the packaging machine, and each cup on this aisle conveyor belt is already a uniform quantity, which can be directly equipped with a pillow packaging machine for rapid packaging;
** 此流程可有效降低更换模具的时间与成本， 更换模具需要更换如下配件：
This process can effectively reduce the time and cost of replacing the mold, which requires the replacement of the following accessories:
*模块 1 机械手吸盘板 Module1 Manipulator suction cup plate
*模块 2 机械手叠放的积料框 Module2 Accumulation frame stacked by manipulator
*模块 3 积料框下方接料的转换板 Module3 Adapter plate for receiving material under the accumulation box
*模块 4 垒杯区整合框 Module4 Cup Area Integration Box
以上配件都是模块化设件， 在更换时， 只需要固定在相应的工位上即可， 所以驱动动力都是伺服电机完成， 可数字化存储每套模具的参数， 更换相应模具， 调出参数就可使用。
The above accessories are modular components, when replaced, only need to
be fixed on the corresponding station, so the driving power is completed by servo motor, can digitally store the parameters of each set of molds, replace the corresponding molds, and call out the
parameters can be used.


(机械手细节图 Detail diagram of robot)


(产品自动整理装置 Product automatic collection device)


6.废边收卷装置(该设备建议配套在线粉碎机）
Waste sheet winding device (suggest to equip with an online Crusher)
5.1 独立收卷装置一套； 收卷装置由恒张力模式收卷；
One set of independent winding device; The winding device is winding by constant tension mode
7.润滑系统 Lubrication system
7.1 模台润滑系统采用全自动润滑装置， 注油频率在人机界面上设定；
The mold lubrication system adopts a fully automatic lubrication device, and the oil injection frequency is set on the touch screen.
7.2 油壶有油位报警功能， 在缺油会在人机界面上提醒操作人员。
The oil can has an oil level alarm function, which will alert the operator on the touch screen when the oil is short.


7. 气动元件 Pneumatic element
7.1 气动元件成型阀与气动压料阀采用美国 MAC 大流量电控阀；
The forming valve and vacuum valve in the pneumatic components adopt the American MAC high-flow electric control valve
A. 主动进气成型阀采用4 组， 减短片材成型吹气时间；
The active intake molding valve adopts 4 groups to shorten the blowing time of sheet molding
B. 气动压边圈气阀采用 2 组， 以高低压形式控制， 对杯口成型压料可控性提高


The pneumatic edge pressing ring valve adopts 2 groups, which is controlled in the form of high and low pressure, and the controllability of the forming pressure material at the cup mouth is improved.
7.2 其余气动控制元件及执行元件均采用台湾亚德客品牌；
The rest of the pneumatic components adopt the Taiwan AirTAC brand;

8. 控制系统 Control system
8.1 整机控制系统人机界面为可推拉的滑轨式安装， 以方便操作；
The touch screen of the whole machine control system is a sliding rail installation that can be pushed and pulled to facilitate operation.
8.2 控制系统采用日本基恩士高性能运动控制器 （最多可控制 256 轴伺服电机）， 对各个伺服电机进行全闭环的控制， 整机伺服电机采用日本安川品牌伺服电机由总线通讯控制， 消除了因为电路的干扰而影响定位精度的问题； 安川伺服是三相 AC220V 系统， 有独立的干式隔离型铜线变压器供电， 变压器置在机器内部， 控制柜配备远程操作模块。
The control system adopts Japanese KEYENCE high-performance motion controller (up to 256 axes servo motor), the full closed-loop control of each servo motor, the servo motor adopts Japanese YASKAWA brand servo motor controlled by bus communication, eliminating the problem of affecting positioning accuracy due to circuit interference; YASKAWA Servo is a three-phase AC220V system powered by a separate dry-isolated copper wire transformer with a transformer inside the machine and a control cabinet equipped with a remote operation module.
8.3 配备 15 寸 MCGS 人机界面， 可远程协助操作；
Equipped with 15-inch MCGS touch screen, remote assistance operation;
8.4 开关、 按钮、 断路器、 接触器及中间继电器均采用法国施耐德品牌；
Switches, buttons, circuit breakers, contactors and intermediate relays are all made of French Schneider.
8.5 接近开关及传感器采用台湾阳明品牌；
The proximity switch and sensor adopt Taiwan FOTEK brand;
8.6 温度系统采用汇川PLC 温控模块， 继电器采用台湾阳明 SSR 固态继电器；
The temperature system adopts INOVANCE PLC temperature control module, and the relay adopts Taiwan FOTEK SSR solid state relay;
8.7 控制柜置于设备的内部， 具有更方便的维护型， 控制柜配备了空调恒温恒湿系统。
The control cabinet is placed inside the equipment and has a more convenient maintenance type. The control cabinet is equipped with an air conditioning constant temperature and humidity system

---