Machine Operator - Injection Moulding & Robots

Education: ITI in Plastic Processing Operator, Diploma in Mechanical, B. Tech in Mechanical 

Moulding Machine HARDWARE:

A.     Toyo Brand: Fully Electric Pressure Japanese IMM 180 Tonne Clamping Force

B.     Prikan Brand: High Speed Hydraulic Pressure Made in India IMM, 110 Tonne Clamping Force.

Mould Mechanical Installation

1.     How to install a new mould on an Injection Moulding machine mechanically.

·       The use of Chain Pulley Blocks, Alignment, Machine Setting Mode Usage, Clamping Torque Force, Scientific Clamps & Platen Mounted Moulds, Precise Alignments as needed for Thin Wall Moulding. Also the Installation of Cooling Lines, Air Flow Ejections through Manifold, Hot Runner Connections and Ejector systems through stripper or ejector rods, depending on which side ejection is planned.

Mould Opening & Closing Stages and Speeds

2.     How to set the distances of Opening, closing and speeds.

·        Outcome: The optimum mould opening distances, stages of speed to avoid jerks and yet minimise cycle time.

Basic settings

3.     How to set the Temperature, Speed & Pressure for Injection & Holding Stages.

·        Outcome: The science of raw materials, Melt Flow Index, range of above parameters per RM, how to go from single stage to multi Stage Injection, Holding, Suck back, Cooling and Plasticising stages. This will ensure no Flash, cuts or deformities and yet optimise cycle time & power consumption.

Optimisation

4.     How to use new age features of parallel cooling, Plastification& Mould opening / closing to minimise cycle time with no impact on output quality.

Outcome: Expertise for reducing costs or increasing output in the same time using the super advanced features in the machines. This will help set the benchmark for KWh per kg calculation, a tough and powerful parameter.

Robots HARDWARE:

A.     Devanshi Brand: Side Entry Robot, Cycle time 6.7 Seconds

B.     Devanshi Brand: Top Entry Robot, Cycle time 6.0 Seconds

Robot Mechanical Installation

1.     With Mould changes, a new cassette, Mandrel and EOAT (End of Arm Tooling) has to be installed. This will happen with each mould alternation.

·        Outcome: The concept of Ejection Clearances (an input to Injection Moulding Machine Parameters), install the above parts and ensure adequate clearances on all sides.

Robot Programming

2.     How program the entire journey from Label pickup, drop into Mould, part pickup and drop onto conveyor using logical steps and inputs of Motors, Air Blow, Vaccum and Static Charge.

·        Outcome: The flow charts, logical steps clubbed together and parallel operations of Cassette, Part drop while Robot arm falls & ejects out of the Mould.

Settings to control Injection Moulding Machine operations through Robot

3.     Part Ejection, Mould Open & Close are controlled using Euro Map 67 connector.

·        Outcome: The handshake timings, delays and safety aspects while minimising cycle time.

Rejection Control

4.     Mandrel settings, Label Fall, Blow Timings and Static use for reducing rejections.

Outcome: This will bring in the much required commercial linkage of reducing losses which happen due to rejections.