O B J E C T / O F F E R No. 605124
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Molding Line
Hersteller: KRAUSS MAFFEI
Typ: KM 1600-3500 DP MC
Produktionsstunden: 801 h
Betriebsstunden total: 3.018 h
Baujahr: 1999
Reduced Price: 495.000,-- € “as it is” EX Germany
Manufacturer: KRAUSS MAFFEI Production hours: 801 hrs
Type: KM 1600-3500 DP MC Operating hours, total 3,018 hrs
Built in: 1999
Price, new €1,000,000.00
Price: bid invited
We are not rendering any guarantees for the completeness of the machine resp. of the accessories listed as many components are subject to wear.
If interested, we shall be glad to send you further records. Inspection date to be agreed upon. Prices to be understood plus VAT. Subject to prior sale.
1 Injection Moulding Machine KM 1600-3500 DP MC
Plastification:
1 cpl. thermoplast plastification in
wear-proof design. Worm diameter
100mm with nonreturn valve and open nozzle
(nozzle radius 40.00mm, nozzle opening 10.00mm)
TECHNICAL DATA:
Clamp unit
- max. clamp power 16000 kN
- max. stamp travel 40mm
- min./max. tool mounting height 850 - 1555mm
- opening width 2390mm
- opening travel of tool at FH min.1540 max. 835mm
- clear width between the columns 1800mm
- clamp platens/fixed part approx. 2360 x 2355mm
- opening power 1250 kN
- total height of clamp unit 7200mm
Injection unit
- working capacity 3500
- screw diameter 100 mm
- L/D relationship 24
- injection pressure 1411 bar
- piston capacity 2411 ccm
- injection volume 801 ccm/s
- screw drive capacity 70kW
- screw speed 119/200 1/min
- torque 5600/3340Nm
- basic height of Y axis 2295 (460) mm
- X displacement 2300mm
- X displacement speed max. 600-800mm/s
- Y swing mechanism approx. 4/4 degrees
- Y swing mechanism approx. 200/200mm
- Z displacement 800mm
- nozzle unit power 60 kN
Slit nozzle
- width min./max. 150-400mm
- strand thickness 6-12mm
- slit nozzle swing approx. 300-400mm
Electro-hydraulic equipment
- nominal capacity, pump motor 90-130kW
- installed heating capacity 65+X kW
- cylinder heating, regulated zones 11
- electr. drive 70kW
Required screw diameters/clamp power/dwell time
Based on the door of the Audi convertible 123 x 70cmm
Aproj = 123cm x 70cm = 8610sq.cm
25% surcharge for partial surface minus 10% for
open regions.
Partial surface = 8610sq.cm x 1.15 = 9901.5 sqcm
Wall thickness s>2mm
Partial volume = 9901.5 sq.cm x 0.2 = 1980.3 ccm
89.22 Pump motors with insulation class F
89.45013 1 service socket, earthed,
10A in switch
cabinet, connected before main switch
89.521 3 start of subsequent
pressure, depending on
inside tool pressure, adjustable on a screen.
Incl. load amplifier
make Kistler, excl. tool pressure
absorber
2 Kistler load amplifiers only for graph computer
and quality control
3 bushings fastened to FWAP BGS
89.591 signal interface per
Euromap 12
(previously FHK 85-12-32)
with waste signal and power supply
socket Cekon 16A for handling unit on firm WAP
89.70 Starting cycle:
change
from starting up to production values for rating
travel, injection pressure, follow-up pressure, bank-up
pressure, depending on rate of shots
89.751 Quality control package:
process monitoring
(actual values of cycles and
integrals) by preset tolerance ranges, indication of actual
value, storage of actual value.
Printable records
89.8033 Super Color TFT screen
in high-brightness design
89.8044 Presentation of graphs on
screen, with tolerance range
and surface monitoring in specific areas for the parameters
follow-up pressure, hydraulic pressure, inner tool pressure
(provided Pos. 89.521 is installed), plastification travel,
injection speed and injection capacity.
Presentation of stamp
travel, follow-up pressure, hydraulic
pressure, 3 x inner tool pressure, plastification travel and
injection speed.Accessories
02.30 1 set of tools
50.40 Deduction for supplying
the machine without
hydraulic central ejector.
Hydraulic and electr. control of ejector will be
included. (No subsequent fitting.)
52.20 In series monitored
"back" position of hydraulic ejector
and of tool ejector plate
62.00 Regenerative pump control system
64.50 Media control for
supervision of oil tub
71.01 Injection stamping cycle
(stamp cycle and
stamp speed to be set at screen)
additional, proportionate quantity control for
achieving a stamping speed of max. 18mm/s.
72.32 Hydraulic core puller
control, 2fold, at movable
WAP (speed and pressure to be set at screen).
Socket assignment per Europmap 13 (Han 16A).
Assembly of core puller valves at BGS
Oil supply for delivery position:
Closing nipple Messrs. Stäubli SBA 087103 PA/JV
Oil supply for injection position:
Clutch Stäubli SBA 081103 PA/JV
72.38 Hydraulic core puller
control, 3fold, at fixed
WAP (speed and pressure to be set at screen).
Socket assignment per Europmap 13 (Han 16A).
Assembly of core puller valves in BGS
Oil supply for delivery position:
Closing nipple Stäubli SBA 087103 PA/JV
Oil supply for injection position:
Clutch Stäubli SBA 081103 PA/JV
89.07 Ejection of cooled down nozzle plug
89.2001 Fan at switch cabinet
89.807 Maintenance instructions:
depending on
performance (operating hours,
cycle periods) the maintenance intervals are
calculated automatically; the screen will show
an alarm once maintenance work will be due.
89.819 Main language German
for screen texts, printer texts and machine plates
89.968 Mainframe interface per specification RS 232.
Adjustment
software for the computer system not
included. To be furnished by supplier of computer.
89.969 BDE interface comprising 5
potential-free contacts on
terminal strip in switch cabinet for connecting BDE
systems such as Kienzle, Datapact, etc.
96.68 Machine coat:
- machine painted in two tints of patterned coating
RAL 5013 cobalt blue
RAL 9002 greyish white
- movable doors RAL 1007 chrome yellow
88.5432 32 temperature controls for hot tool channel.
Adaptive controls
(self-optimizing), including
plug and socket connection Han 16 E for capacity
and Han 16 A for temperature feeler.
Plug assignment per Euromap 14.
Capacity per control point max. 2 kW
Capacity per control point max. 3.6 kW
Plug type and assignment per Peguform standards.
Control points for
tool heating furnished with fusible
cut-outs (Socomec) 16 A. Each range separated into
5 outlets furnished with fine fuses 6.3 A with failure
alarm.
72.70 5 twin check valves for holding the cores
72.60 Pressure maintaining pump for core puller
63.63 Full-flow filter after
all hydraulic pumps
(exception: axial piston pump and pressure
maintaining pump for core puller
Clamp unit, vertikal, with reversed columns.
The clamping mechanism is located at the BFAP.
Raised clamping unit by 585mm by substructure.
Distance FFAP - nozzle centre (in lowest position)
460mm.
FEH min. 850mm
FEH max. 1555mm
Opening width max. 2390mm
Opening power
(1250KN) less the weight of the
moveable tool half.
Injection unit incl. machine bed same as KM 420/3500 DP
Order 644023/2.
With modification for 110 kW pump group (re. SP 4350/5700).
Power of the nozzle
unit to be started at the lowest position
only (basic height = 2190mm).
Automatic positioning
travel of the unit during the injection process
in longitudinal direction of the machine (x-axis).
Automatic height adjustment of the unit (z-axis).
Manual swivel mechanism in the horizontal position of the unit.
12fold cascade
control, hydraulic. Double-acting valves for
shut-off needle nozzles. Each nozzle is separately opened
and
closed depending on screw travel.
Special controls for
closing the nozzles as in order 607483
(No. 326619H4)
1) Closure depending
on travel, or at end of follow-up pressure,
at the latest.
2) Closure depending on travel or at a delay at start of follow-up
pressure.
Initial oil flow for opening the needle:
Clutch Stäubli SBA 08.1103 PA/JV
Initital oil flow for closing the needle:
Closing Nipple Stäubli SBA 08.7103 PA/JV
Pressure relief for cascade control.
- Safety doors at BS and face side (SS) of clamp
- Design in several parts by telescope principle
- Operating panel at
cornerBS/SS movable so that
operation will be possible from BS and SS while
watching the complete clamp area.
- Plugged operating panel allows for easy disassembly
- Integrated acknowledgement button
- Platform with
safety appliance at BGS at the level of
the clamp area of the FWAP for plugging the media
connections
- Access through safety door at the SS via customer's
working platform. (Included in point 4.5)
Manual production process without robot in HA operation
- Tool and safety door at SS open (door at BS always remains shut)
- Bringing in of clamp frame with decor into inner tool area.
- Positioning and
fastening at upper part of tool with pneumatic
cylinder.
- Triggering of the
tool valves via push-buttons, for BS and
BGS each (switch box fastened at tool).
- Parallel release via core puller software
- Operation of vacuum valves (switch box fastened at tool)
- Leaving the inner tool area, release of safety bolt, closing of
door, acknowledgement, closing and injection.
- Opening of safety doors while the tool is open.
- Removal of clamp frames and finished workpiece
Automatic production process with robots in VA-operation
- Operating panel
plugged to sheathing BS between clamp
and injection unit
- Housing of robots with safety doors
- One robot will insert clamp frame of SS
- Pneumatic fastening
of clamp frame via robot signal.
Operation of vaccum valves integrated into process
(possible robot signal).
- Further details
about automatic operation to be discussed with
customer.
Electric motor driven screw drive
Software and electric
for 3 separate vacuum cycles, one pump
per cycle (Becker, type 114.100 SA/K), one vacuum valve,
one ventilation valve. Activation via operating panel.
First start-up of pump by "Vacuum On".
Pump switches off
upon expiration of pre-selected interruption
period.
"Vacuum Off" with selectable delay after the start of injection.
Negated control of ventilation valves by vacuum valves.
Additional information under pt. 104.2-104.5.
Assembly of pumps and valves on top of BWAP.
Pumps and valves furnished by Peguform.
Preparation of
machine for Stäubli clamp system,
consisting of:
Drilling pattern in FFAP and BFAP
One hydraulic valve
for FWAP; 2 hydraulic valves for
BWAP (safety cycle)
Intgration of control into MC3 F
Assembly of mech., electr., hydr. function test. Data about
position and size by Mr. Zobel (Peguform).
Grooves for Enerpac
lifting ledges (width x depth 28x48mm)
and centering guide/central guide (width x depth 30x5) as
well
as drilling pattern for consoles at FFAP. Tool insertion
either BS
or face side.
Data defined by Mr. Zobel (Peguform)
Special control
system for operating the hydraulic lifting ledges
in E-operation (exclusively) while the machine is open and
with
activated key switch (identical with order 644023).
Supply of cooling
water at FWAP and BWAP (via energy chain)
at BGS each.
Max. temperature 95°C.
Each one cycle with 1 1/4" hose at bulkhead plate.
Connection to tool
(bulkhead inside thread 1") with screwed nipple
(Stäubli MAM 155 155 LN) and plugged nippled (Stäubli
GPL 25.6105)
Wedge-type machine support for injection unit, make Bilz
12 anchor screws
M36x400 DIN 529, to be supplied to customer
at first.
4) Closing of nozzle
after end of follow-up pressure and
compression relief before plastification.
5) Delay times (to be
set via screen) for opening and closing
of nozzle each.
Two tank connections
K 1 1/2" with one stop valve each for
external oil filter, make Peguform.
Provision of oil collecting tub by Peguform.
Design to be agreed upon with KM.
Socket combination:
2 x earthed 16 A
3 x CEE 32 A
positioned beneath switch cabinet
Software for special
control system (Decoform)
Closing power profile depending on screw travel, incl.
hardware electronics, hydraulic, additional graph
"closing
power (kN)" and "tool breath (mm)" via
"injection period (sec)".
Including the inductive displacement pick-up of the
amplifier
board and wiring (assembly at the tool not included).
System separation (simultaneous injection - stamping).
VERTICAL MACHINE FOR
SOURCE FLOW AND STRAND
POSITIONING
Process description source flow
- Closing of tool until s27 (stamp travel < 40mm)
- Start of injection
- and start of simultaneous, screw travel-depending
closing power profile (stamping)
- Cooling period
- Plastification
- Opening of tool
- Ejection
Process description strand positioning
- Advance of
injection unit upto a defined
travel point of the X-axis
- Start of injection
- and start of X-axis (return stroke of aggregate)
- and start of Y-axis
- Closing of tool until s27 (stamp travel < 40mm)
- Start of stamping profile
DESCRIPTION OF PEGUFORM PROCESS
- Bringing in of
pre-shaped skin or foil with
pre-shaped insert into movable tool side (top)
and clamping with vacuum
- Or bringing in of
pre-heated foil with clamping frame
into movable tool side (top) and clamping with vacuum.
- Closing of tool until stamp travel is achieved.
- Advance of tool slider at upper side of tool
- Forward travel of injection unit
- Start of injection
and start of screw travel-depending
closing power profile
- Cooling phase
- Plastification
- Back travel of slider
- Opening of tool and ejection of workpiece with core puller
- Discharge of
workpiece with robot during the
tool-opening phase or after the tool-opening phase.
Stamping of opening,
max. stamp travel 40mm with
3-stage speed profile.
Start depends on screw travel.
Additional block
including tank pipe 50x3 (3000 psi) for
achieving a speed of approx. 18mm/s.
Slit nozzle
- Width min/max 150-400mm
- Strand thickness 6-12mm
- Radius of slit nozzle approx. 300-400mm
Stepless width regulation, programmable by automatic lid system.
Variable strand thickness by changing of insets.
Procurement by KA 12.
The dead weight of
approx. 300 kg requires a support
(jib (drwg. 669 7698).
Adjustment of injection housing.
Instructions about
operating materials same as with
KM 3200 (No. 32C619H4).
Preparation for the pre-heating of materials.
Software and optional
programme with modification
or robot interface.
Use of each one
regulating point for basic capacity resp.
production performance, pre-setting of performance via
ED regulator. Performance made available at machine
socket. Design as with KM 250 DF No. 2034470.
Density (PP+20Talk.) = 1.04g/ccm
Unit weight = 1980.3 ccm x 1.04g/ccm = 2059.51g
Yield factor 0.85
Stroke volume = 2059.51 / 0.85 = 2422.95ccm
150 bar inside pressure/closing power
Fs = 8610 sq.scm x 1.5kN/sq.cm = 12915 kN
Dwell time = tv = xa 87 sec.
At a minimum shot
weight of 800 the yield is 39%,
at a dwell time of 226 sec.
Dates:
BAS 01/12/98
End of assembly 02/02/99
End of commissioning 25/02/99
End of test runs 30/04/99
Tests about continuous operation to be agreed upon with Mr. Klotz!
Special control
system: opening of the single vacuum
valves depending on closing travel via screen input
Additional supply of
pneumatic core puller for fixing
the clamping frames for robot operation
(electr. hardware and software only).
Amplification of
power for the pre-heating of materials
(regulating point 33 and 34), so that totally approx. 28kW
will be available.
Additional supply of
cover plates for cable conduit beneath
switch cabinets.
Exchange of
impuls-controlled pneumatic valve (SN 6253156)
against 5/3-way valve "deaerated in centre
position" (SN
6438446).
