宝洁公司注塑成型车间培训资料

VersionVersion1.0/ToolTechnologyBSL#OperatingandPreventive

MaintenanceGuidelineforHighPerformanceInjectionMolding高效注射成型的操作与预防保养指南NOTE31SAFETYGUIDELINE安全方针32MOLDSET-UPPROCESS模具上模程序53HEATING-UPPROCESS加热程序64START-UPPROCESS开始程序75DURINGPRODUCTION生产过程76COLOUR/MATERIALCHANGE换色/换料87MAINTENANCE保养87.1General概要87.2Shiftchange日保养87.3Weekly周保养97.4Howtocleanthemold如何清洁模具98TAKINGOUTOFSERVICE下模保养98.1Forshortterm短期98.2Forlongterm(>3month)长期（>3个月）109MALFUNCTION故障109.1Incaseonecavityblocked万一有一穴堵住109.2Lossrangeoftolerancebyplasticparts产品偏离公差范围119.3Getanoisyscrew(injectionunit)螺杆有噪音（射出单元）119.4Blackdots黑点119.5Deviationofpartwallthickness产品壁厚偏差1110GENERALINSTRUCTION通用作业指导书12Note注释Toassurewarrantyoffitnessforbestmoldfunctionandbestpartquality:为确保最佳的模具功能和最佳的产品质量的合理的依据Allcleaning,serviceormaintenanceintervalshavetobedocumentedbyresponsibleperson!所有的清洁，维修与内部保养，责任人须将其文件化Nobodycanexpectahighlypartqualityifthemoldisdirty,wornout,wrongadjusted,badlymounted,notproperlycooled,moldingparametersarenotadjustedaccordingtomaterialdatasheetorotherrelateddevicesarenotworkingproperly.如果模具脏污，破损，错误的调整，安装不好，不正确的冷却，工艺参数不是按按照材料的性能数据表设定，或其它的辅助设备工作不正常，就不可能得到合格的注塑产品。Anyrecommendationforguidelineimprovementormissingitemswithinthisdocumentarewelcome!对本指南尚需改进的地方或疏漏之处，欢迎提出宝贵建议！SafetyGuideline安全方针Beforeproceedingpleasereadthedetailsofthisguidelinecarefullytoavoidmoldormachinedamageoraccidentsbymishandlingthemoldorequipmentorthemachinecontrolorthemoldingmachineitself!为避免错误的操作机器或设备，或模具，或机器控制系统，导致模具或机器的损坏或事故，请在进行操作之前仔细的阅读本指南。Beforeoperatingthemoldor/andcontrolsystemaspecialistshouldcheckallelectricalconnections.Itshouldmatchlocalrequirementsorguidelinesfromyourcompany(e.g.hotrunnerconnection!)。在操作模具或机器控制系统前，必须由专业人员检查电器的连接，机器或模具必须与工厂内的要求或指导方针相一致(比如热流道的接线方式)Neverbypassanelectricalfuse.任何情况下，不能对保险丝连接旁路。Avoidanywatercontactofanyelectricalconnectorordevice!避免水接触到电子连接处或设备Incaseofwatercontactitisnecessarytodryallpartscarefullybeforeputtingintooperationagain!万一水接触到电子元器件，在运转之前，首先将湿的零件擦拭干燥好。1.5?Afteranyinterruptionorbreakofmoldingprocessthemoldshouldheated-upsmoothlywithreducedtemperaturetogetallheatersdriedofexistingcondensationwaterfsoftdryingprocess.生产中断后，应该慢慢升高模温，以用来除去冷凝水。1.6?Incountrieswithhighairhumiditylevel,theheating-upprocesshastobedonewithdelayedtemperatureincreaseeverytimebeforestartrunningfthisistoassureadrysystemandtoremoveexistingcondensationwaterfromthesystem..在高湿度的地区，在开始之前应使用延迟加热，这是为了确保一个干燥系统和除去系统中存在的冷凝水

Allscrewconnectionshavetobecheckedbeforeoperating(moldplate,ejectorunit,inserts,pressureplates,etc.).运转前，必须检查所有的连接的螺丝(如模板，射座，型芯上的)Aftereveryinterruptionorbreakofproductioncheckthemoldmovementareasandassurethatthesliderareattherightposition.每次生产中断后，须检查模具动作的区域，确保滑块在正确的位置Beforedemountingthemoldallsafetypartshavetobeassembled,i.e.ejectorplatelockormoldprotectionlock.在下模之前，所有的安全部件必须装上，如顶板锁定块，模具保护块等。Weeklycheckofallcooling/heatinghoses.Exchangebrittlepipes/hoses!每周检查冷却/加热的软管，更换变脆的软管。Weeklyallcouplingsofthehoseshavetobecheckedforpropersafetyfunction.每周检查管路的快速街头是否脱落，确保操作者安全。Dailychecktheejectorcouplerfortightfit.每日检查顶杆连接处的固定情况Dailychecktheejectorstrokeforcorrectadjustment.每日检查顶杆的顶出位置并正确调整Usethesetupforthemoldprotectioninthisway,thatthereisnopossibilitytodamagethemolddueforeignsubstanceormechanicalreason.Theclampingforceshouldtocomeineffectwhenthemoldplatesareincontact.使用准备模式，可以对模具进行保护，防止因不相关的物质或机械原因，导致对模具的损坏，此时只有在两模板接触到时才会产生锁模力。Neverinjectintoanopenmoldwithoutpurposeoradditionalprotectionofmoldinserts.在模具打开且型芯没有外加防护的情况下，禁止向模具内射料。Pleasewearsuitableglovesforcleaningorrepairingthemoldtoavoidinjury.为避免伤害，在清洁或修理模具时请戴上手套。Byoperatingwithhotelementsorhot-runnerelementseverytimesuitablesafetyglovesmustbeworn.每次操作热的元器件或热流道器件，必须戴上合适的安全手套Switchoffthevoltagetogetnoriskofmanipulationduringalongturninterruption.在机器长期停止期间关闭电源，以防止给操作者带来危险。Neverstartrunningwhenthesafetyguardgateisopenandneverdisassembleanysafetyswitchorsafetyequipment!1.7.1.81.91.101.111.121.131.141.151.161.171.181.19禁止在安全门打开时开始操作机器，禁止拆卸任何安全开关或安全设备。MoldSet-UpProcess上模程序Togeta100percentparallelismcleanthemachineplateandthemoldplatewithacloth,sothattheyarefreeofrust,chippingetc.为获得100%的平行度，须用抹布清洁机器模板和模具模板上的锈，碎片等。Fixthemoldtothemachineplateontheinjectionsidewithacenteringring,screwitandclosethemovingmachineplateinsetupmodus(reduceclampingpressure/force;reducehydraulicpressure).Insomecases(handlingsystemorverticalinjectionunit)adjustthemoldwithawaterlevel.使用定位把模具安装在射出侧，用螺丝定位后，在准备状态下(为减小锁模力/压力，液压压力)，合上模板，调整模具水平。Calibratethemoldheight(setupmodus).在准备状态下，调模厚Screwthemoldplatewiththemovingmachineplate.用螺丝把模具动模侧固定好Openthemold(setupmodus).在准备模式下开模Coupleandthanadjusttheejector(setupmodus).Avoidthattheejectorgoesblocktootheoppositeplate.Ensurethattheejectorisatthebackposition.在准备状态下连接并调整顶杆，避免顶杆卡死。确保能回到正确的位置Connectwater,airandelectricity.连接水，气和电路Assureallconnectionsareinstalledproperly.Checkwithairwhetherallcyclesareconnected.确保所有的连接安装正确，使用气枪检查是否所有的回路都被连接Assurewaterhosesarenottoolongortooshort,sothatthereisnooverbendingorrubbingagainstanysharpedgeorobstacle.确认水管不是太长或太短，避免弯曲太大或与尖的边缘或障碍物摩擦Switchonthecoolingsystem(controller)andcheckthatnohoseorcouplerisleaky.打开冷却水开关，检查水管与接头无漏水Checkthatthereisnoleakyspotinthemold(cavities,moldplates,sliders).检查模具型腔，模板，滑块是否漏水Note:Anyleakyspotcandamagethesteelduetoburningwaterspotonsteelsurface!注：任何漏点都可能因钢材表面的气化水点导致损坏钢材Adjusttherightstrokeandvelocityforthemold.Forfirstsetupandfirstmoldclosingmovementreducetheclosingspeedtoaminimumtoavoidanddamage(setupmodus)!Forproductionalsoadjusttheclosingmovementtoalowerspeedwhenguidepinsandangularpinsstarttoproceed.正确调整模具的位置与速度，第一次模具架模与第一次模具闭合，在准备模式下，降低至最小速度以避免损坏模具。在生产时，当导柱或有尖角的型芯接触时，也须调整锁模速度慢一些Note:Guidepinsshouldbeslightlygreased,andneverrundry!注：导柱必须涂上适量润滑油脂，禁止无润滑油脂运转Closeandopenthemoldafewtimesandcheckwhetherthemovementiscorrect(setupmodus).在准备模式下，开合模几次，检查动作是否正常Switchonthehotrunneraccording3.5.依照3.5章，打开热流道Themoldhastobeclosedduringheatingprocess.在加热过程中，模具应处于合模状态Whenthemoldreachestherequiredtemperatureopenandclosethemoldagain(setupmodus)andrecheckthemoldheight,thanaddtheclampingforce(manualmodus).当温度至设定的温度时，再次在准备模式下开合模，再次确认模厚，在手动模式下加上锁模力Onlyusewaterwhichisneutral(PH-value7.1-7.5),toachievewaterrequirementsthewaterhastobetreated.使用的水必须是符合水质要求，经过处理的中性水(PH值在7.1-7.5间)Cleancavities,slidersandpartingplanesothattheyarefreefromrust,shadows,filmlayerorothersubstances.Usesuitablerubbertocleanallvisiblesurfacesonaregularbase.清洁型腔，滑块和分型面以防止模具生锈，产生暗影，形成塑料薄层等。用专用的橡胶笔定期清理模具表面。Adjustapropermoldprotectionandrecheckthesettingstoavoidanymolddamage.正确调整模具的保护，重新检查设定，避免任何的模具的损坏Heating-upProcess加热程序Moldhastobeclosedwithoutclampingforce(setupmodus).在准备模式下，合上模具，处于无锁模力的状态Switchonthetemperature/coolingcontrolsystem.Assureallsystemsaresealed.打开模温控制系统，确保系统密封良好Switchontemperaturecontroller.打开温度控制器Switchonthehotrunnersystemwithdelayedheating-upcurve.使用延迟加热方式打开热流道系统，Firstlythehotrunnertemperatureshouldbeadjustedtoabout100degreeforapprox.10minutes.Thisistoassurethatapotentialhumiditylayer(condensationwater)isevaporatedbeforeheating-uptomaximumtemperature.首先调整热流道温度到100摄氏度，保持10分钟，目的是为了保证潜在的水层(凝结水)在加热至最高温度前蒸发掉。Duringtheheating-upprocesscheckthefunctionofthehotrunnerbyusingthecontrolsystem(e.g.checkcurrentvalueforeachnozzle).Hereyoucancheckalreadywhetherthehotrunnerisproperlyworkingandinrangeoftoleranceforeachheatingzone.在加热过程中，首先检查热流道的功能(如每个喷嘴的实际值)直到热流道正确工作且每个加热区在公差范围内。Checkmaterialdatasheetforcorrecttemperatureadjustment..依材料物性表调整温度Whentheprocesstemperatures(mold,hotrunner)arereachedadjustthemoldheight(setupmodus),thenswitchovertomanualmodustoset-uptheclampingforce.当制程温度(模具，热流道)到达后，在准备状态下调整模厚，然后切换至手动模式，设定锁模力Recheckthemoldprotection(bypressureandtime).再次检查模具保护设定(压力和时间)Start-upProcess开始程序Startthemoldingprocesswhenallprocesstemperaturesarereached.(mold,hotrunner,nozzle,barrel).在所有的温度(模具，热流道)到达后开始注塑制程Beforetheinjectionprocessisgoingtostart,spoutfewtimestheaggregate.Thisistoassurebestpossibleinprocessmaterialcondition.在注塑之前，空射几次，目的是为了确保最好的材料状况Themachinenozzlehastofitthemoldbushcorrectly(checkthepositionortouch-upwithapieceofpaper).However,thismayvaryfromdifferentnozzlefittingsystems.机器的喷嘴必须与模具浇口套相配合良好(使用一张纸检查位置与接触状况)Forfirstsamplingalwaysstartwithafillingstudy.Takecarethatnocavityisoverloaded.Startwithasmoothadjustment.Storethefillingstudyparts.经常在第一次试模时进行充填分析，注意不可过度充填，开始时进行微调。保留充填分析的样品Accordingtothefillingstudyresulttrytobalancethehotrunnernozzlesforeachcavity.根据充填分析结果，对每个热流道进行调节以达到平衡Afterapprox.98percentfillgradeswitchovertoholdingpressure.大约充填至98%时，转换为保压阶段Holdingpressuretimedependsofgateandpartdesign;Takeweightoftheplasticpartswithoutspruetogetthecorrectholdingpressuretime.保压时间取决于浇口与产品的设计，通过称量产品的净重以获得合适的保压时间Note:Ifgateisfrozen,noholdingpressurewillbeactiveinthepartandpartweightcannotbeincreasedanymore!注：如果浇口已冷却，保压不会再对产品产生效果，产品的重量不会再增加Choosetheproperadjustmentofinjectionvelocitytofillthecavities,dependingofpartdesign,partthickness,moldtemperature,surfacequalityetc.依据产品设计，壁厚，模温和产品的表面质量，选择合适的充填速度。Choosethepropercoolingtimetoachievebestpossible(necessary)partquality.选取合适的冷却时间以获得最优的产品品质Checkthepartquality(surface,sinkmarks,jointlines,shrinkage,warpage,etc.)检查产品的质量(表面外观，缩水，结合线，收缩，翘曲等)Payattentionthatthesprueandplasticpartsareeasytoreleaseduringejectionstroke.注意产品在顶出过程中，料杆与产品是否容易脱模Incasestherearestickingplasticpartsatthecoreonlyusecooperorbrasstoforcethesparts.万一有产品粘在型芯上，只能用紫铜或黄铜工具去除Duringproduction生产过程Theejectorplateshouldnotgoblock.顶针板不可被卡死Avoidthatthereisjammedplasticmaterialinanymoldarea.避免在模具的任何地方存在压碎的塑料原料

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.选择合适的射出压力与时间，以避免过度充填Checkthecoolingwatertemperatureandtheflowrate.检查冷却水的温度与流速Colour/materialchange换色与换料Stopthematerialsupply.停止原料供应Produceuntilthescrewdoesn'trpelascthifictahteionstroke.继续生产直至螺杆无法达到计量位置Cleanthehopper,thenozzleandthefeedbush清洗原料储料筒，喷嘴和浇口套Spoutaggregateuntiltheextrusionmaterialisclean/regular射料直至射出的料已干净/正常Maintenance保养General概要Checkallscrewsofinjectionmold.检查模具上的所有的螺丝Checkwhethertheejectorunitisloose.检查顶出杆是否松动Inspectcouplings,waterhoseandhydraulichosewhethertheyareleaky.检查接头的连接，水管各液压管路是否泄漏Checkcontrolsystems,i.e.hotrunnersystem,coolingsystem.检查控制系统，如热流道，冷却系统Checkmoldprotectionadjustment(timeandpressure).检查模具保护的时间与压力Inspectregularallmachineparameters,i.e.backflowblockade,pv-regulator;takecareforit.定期检查机器的参数，如止逆阀，Checkairsystemforleackage.检查气路是否泄漏Takecarethattherearenoforeignpartsorplasticpartsbetweenthepartingareasorbetweensliders,ejectorplate,etc.检查产品成型型芯，滑块间，顶板间，没有其它无关的物品或料料产品Shiftchange日保养Cleanworkingarea.清洁工作区域Cleancavitiesandpartingsurfaces.清洁型芯和分型面

Comparemoldingdatasheetwithsetup.Incaseofsomedeviationspleasemakedocumentation.比较设定值与实际值，如果有不同的冲突的地方，进行文件更改7.3Weekly周保养Cleanguidingelementsandrenewifnecessaryalllubrications.清洁导向部件，必要时更换润滑油Disassembleandcleanslider,coreandstripperplate.卸下滑块，型芯和顶出板并清洁Inspectthecoolingsystem,checkthewaterflowrate/pressure.检查冷却系统，检查水压及流量Checkthewaterquality,PH-value.检查水质，PH值Checkallscrewsinthemold.检查模具上的所有的螺丝Cleanthefeedbushandthenozzleoftheinjectionunit.清洁浇口套，喷嘴Howtocleanthemold如何清洁模具Useclothandethylalcohol(spirit).使用抹布和乙醇(酒精)Clothshouldbemadeofcotton.必须是棉布Ifitisnotfeasibletocleanwithaclothusepolishpaste,becarefulanduseonlyafinepaste(donotpracticeonEDMsurfaces).如果在抛光面上无法使用抹布，则只能使用研磨膏，仔细的使用细的研磨膏。(不要在放电面上使用)TocleantheEDMsurfacefromfilm/disposaluseonlyspiritor/andsuitablerubberpen.清除放电面上的塑料薄层，只能使用皮纹清洗膏(涂皮纹清洗膏于需清理处，使用软毛刷轻轻地刷除)或合适的橡皮笔清除。Takingoutofservice下模保养Forshortterm短期保养Switchoffhotrunnersystem.关掉热流道系统Spouttheinjectionunit.射空料管中的料Formaterialswitchover(type)usecleaner(PP)tocleantheaggregate.如更换材料类型，使用PP料清洁。Switchofftheinjectionunit.关闭射出单元Switchoffthecoolingcontrollerforthemovingplate.Fortemperaturesatabout/over70/80Ccooldown(controllerfunction).关闭动模的冷却系统，如果模温在70/80摄氏度的，要启动冷却功能按钮。Thecoolingsystematthestationaryplate(wherethehotrunnerisconnected)shouldrununtiltheplatetemperatureislessthan100degreeCelsius.Switchoff.定模板的冷却系统(热流道安装处)须在温度降至100度以下时方可关闭。Useexhaustfunctionbycoolingcontrollerswhereitisavailable.用模温机的倒吸功能现将模具中的水排回。Blowthewateroutofthecoolingpipes(airpistol).使用气枪吹干水管Beforedemountthemoldithastocleancareful.下模之前仔细清理模具Userustinhibitortoprotectthemold,especiallythecavities.使用除锈剂保护模具，尤其是型腔Forlongterm(>3month)长期保养Ifthemoldgoesoutofserviceformorethanfewweeksitistodisassemble,toclean(spirit,polishpaste,etc.)andtospray(rustinhibitor)carefully.Especialcleanthecavities,partingplane,etc.如果模具超过几周没有保养，清理模具(必要时抛光)，仔细喷防锈剂，尤其是型芯，分型面Guideelementsormovingpartshavetobegreased.导向部件或移动部件须涂上润滑油Electricalplugshavetobecovered.电插头必须盖住Coolingconnectionshavetobecoveredwithplasticnipples.冷却水接头须用塑料封住Malfunction故障9.1Incaseonecavityblocked堵穴情况Checktheheat.检查加热Checkthegate.Disassemblethegateinsert(hotrunner)andgiveavisualcheck.Cleanit.Reassemblebuttakecarefortheseals.检查浇口，卸下浇口型芯(热流道)，目视检查，清洗，重新组装，注意密封状况Whenthereisakindofforeignsubstancekeepit,analyseitanddocumentit.当有异常的物质存在时，分析并在文件中记录Emptythehopperandcheckthematerial.清空储料筒并检查原料Spouttheinjectionunitfewtimes.-空射料筒中的原料几次Spoutthehotrunnerbeforeyoureassemblethegateinsert.Becareful,useonlythefunctionplasticizes,sothereisalowpressure.Neverusethefunctioninjectionwhenthegateisdisassembled.拆卸热流道浇口处型芯前，首先要射空热流道里的料。注意，只能用塑化功能来挤出(此时压力低)，千万不能在浇口拆下状态后射料。Lossrangeoftolerancebyplasticparts产品超出公差范围Checktheinjectionprocesssetup(temperatures,times,velocities,pressures,etc.)检查工艺设定(温度，时间，速度，压力等)Checkcoolingsystem检查冷却系统Getanoisyscrew(injectionunit)螺杆噪音Assurethatthecylinderheathavethepropertemperature确认加热温度正常Assurethatthetraversetemperatureisnottoohigh确认下料口温度不是太高Observetheplasticizespeed观察塑化速度Doublecheckmaterialresignsforanypollutionandforeignmaterial再次检查原料粒子是否被污染或混入其它原料Checkthesizeofregranulate/repellits检查回料颗粒的尺寸Disassemblethescrewandcheckforanydefectandscratches.拆螺杆检查是否有划伤和其它缺陷Blackdots黑点Cleancompleteinjectionunit.清洁注塑单元Assurethatthehotrunnertemperature