宝洁公司注塑成型车间培训资料

宝洁公司注塑成型车间培训资料宝洁公司注塑成型车间培训资料宝洁公司注塑成型车间培训资料OperatingandPreventiveMaintenanceGuidelineforHighPerformanceInjectionMolding高效注射成型的操作与预防保养指南Note 31 SafetyGuideline安全方针 32 MoldSet-UpProcess模具上模程序 53 Heating-upProcess加热程序 64 Start-upProcess开始程序 75 Duringproduction生产过程 86 Colour/materialchange换色/换料 87 Maintenance保养 87.1 General概要 87.2 Shiftchange日保养 97.3 Weekly周保养 97.4 Howtocleanthemold如何清洁模具 98 Takingoutofservice下模保养 108.1 Forshortterm短期 108.2 Forlongterm(>3month)长期（>3个月） 109 Malfunction故障 119.1 Incaseonecavityblocked万一有一穴堵住 119.2 Lossrangeoftolerancebyplasticparts产品偏离公差范围 119.3 Getanoisyscrew(injectionunit)螺杆有噪音（射出单元） 119.4 Blackdots黑点 119.5 Deviationofpartwallthickness产品壁厚偏差 1210 GeneralInstruction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！1 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。1.1 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）1.2 Neverbypassanelectricalfuse.任何情况下，不能对保险丝连接旁路。1.3 Avoidanywatercontactofanyelectricalconnectorordevice!避免水接触到电子连接处或设备1.4 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-upsmoothlywithreducedtemperaturetogetallheatersdriedofexistingcondensationwater→softdryingprocess.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-upprocesshastobedonewithdelayedtemperatureincreaseeverytimebeforestartrunning→thisistoassureadrysystemandtoremoveexistingcondensationwaterfromthesystem..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1.7. 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）1.8 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1.9 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。1.10 Weeklycheckofallcooling/heatinghoses.Exchangebrittlepipes/hoses!每周检查冷却/加热的软管，更换变脆的软管。1.11 Weeklyallcouplingsofthehoseshavetobecheckedforpropersafetyfunction.每周检查管路的快速街头是否脱落，确保操作者安全。1.12 Dailychecktheejectorcouplerfortightfit.每日检查顶杆连接处的固定情况1.13 Dailychecktheejectorstrokeforcorrectadjustment.每日检查顶杆的顶出位置并正确调整1.14 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。1.15 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。1.16 Pleasewearsuitableglovesforcleaningorrepairingthemoldtoavoidinjury.为避免伤害，在清洁或修理模具时请戴上手套。1.17 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1.18 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。1.19 Neverstartrunningwhenthesafetyguardgateisopenandneverdisassembleanysafetyswitchorsafetyequipment!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。2 MoldSet-UpProcess上模程序2.1 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。2.2 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。2.3 Calibratethemoldheight(setupmodus).在准备状态下，调模厚2.4 Screwthemoldplatewiththemovingmachineplate.用螺丝把模具动模侧固定好2.5 Openthemold(setupmodus).在准备模式下开模2.6 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2.7 Connectwater,airandelectricity.连接水，气和电路2.8 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2.9 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2.10 Switchonthecoolingsystem(controller)andcheckthatnohoseorcouplerisleaky.打开冷却水开关，检查水管与接头无漏水2.11 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2.12 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2.13 Closeandopenthemoldafewtimesandcheckwhetherthemovementiscorrect(setupmodus).在准备模式下，开合模几次，检查动作是否正常2.14 Switchonthehotrunneraccording3.5.依照3.5章，打开热流道2.15 Themoldhastobeclosedduringheatingprocess.在加热过程中，模具应处于合模状态2.16 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2.17 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）2.18 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。2.19 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3 Heating-upProcess加热程序3.1 Moldhastobeclosedwithoutclampingforce(setupmodus).在准备模式下，合上模具，处于无锁模力的状态3.2 Switchonthetemperature/coolingcontrolsystem. Assureallsystemsaresealed.打开模温控制系统，确保系统密封良好3.3 Switchontemperaturecontroller. 打开温度控制器3.4 Switchonthehotrunnersystemwithdelayedheating-upcurve.使用延迟加热方式打开热流道系统，3.5 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。3.6 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。3.7 Checkmaterialdatasheetforcorrecttemperatureadjustment..依材料物性表调整温度3.8 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3.9 Recheckthemoldprotection(bypressureandtime).再次检查模具保护设定（压力和时间）4 Start-upProcess开始程序4.1 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4.2 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4.3 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）4.4 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4.5 Accordingtothefillingstudyresulttrytobalancethehotrunnernozzlesforeachcavity.根据充填分析结果，对每个热流道进行调节以达到平衡4.6 Afterapprox.98percentfillgradeswitchovertoholdingpressure.大约充填至98%时，转换为保压阶段4.7 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4.8 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。4.9 Choosethepropercoolingtimetoachievebestpossible(necessary)partquality.选取合适的冷却时间以获得最优的产品品质4.10 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）4.11 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5 Duringproduction生产过程5.1 Theejectorplateshouldnotgoblock.顶针板不可被卡死5.2 Avoidthatthereisjammedplasticmaterialinanymoldarea.避免在模具的任何地方存在压碎的塑料原料5.3 Choosetheinjectionpressureandtimetoavoidoverstressinthemold.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6 Colour/materialchange换色与换料6.1 Stopthematerialsupply.停止原料供应6.2 Produceuntilthescrewdoesn’treachtheplastificationstroke.继续生产直至螺杆无法达到计量位置6.3 Cleanthehopper,thenozzleandthefeedbush清洗原料储料筒，喷嘴和浇口套6.4 Spoutaggregateuntiltheextrusionmaterialisclean/regular射料直至射出的料已干净/正常7 Maintenance保养7.1 General概要7.1.1 Checkallscrewsofinjectionmold.检查模具上的所有的螺丝7.1.2 Checkwhethertheejectorunitisloose.检查顶出杆是否松动7.1.3 Inspectcouplings,waterhoseandhydraulichosewhethertheyareleaky.检查接头的连接，水管各液压管路是否泄漏7.1.4 Checkcontrolsystems,i.e.hotrunnersystem,coolingsystem.检查控制系统，如热流道，冷却系统7.1.5 Checkmoldprotectionadjustment(timeandpressure).检查模具保护的时间与压力7.1.7 Inspectregularallmachineparameters,i.e.backflowblockade,pv-regulator;takecareforit.定期检查机器的参数，如止逆阀，7.1.8 Checkairsystemforleackage.检查气路是否泄漏7.1.9 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7.2 Shiftchange日保养7.2.1 Cleanworkingarea.清洁工作区域7.2.2 Cleancavitiesandpartingsurfaces.清洁型芯和分型面7.2.3 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7.3 Weekly周保养7.3.1 Cleanguidingelementsandrenewifnecessaryalllubrications.清洁导向部件，必要时更换润滑油7.3.2 Disassembleandcleanslider,coreandstripperplate.卸下滑块，型芯和顶出板并清洁7.3.3 Inspectthecoolingsystem,checkthewaterflowrate/pressure.检查冷却系统，检查水压与流量7.3.4 Checkthewaterquality,PH-value.检查水质，PH值7.3.5 Checkallscrewsinthemold.检查模具上的所有的螺丝7.3.6 Cleanthefeedbushandthenozzleoftheinjectionunit.清洁浇口套，喷嘴7.4 Howtocleanthemold如何清洁模具7.4.1 Useclothandethylalcohol(spirit).使用抹布和乙醇（酒精）7.4.2 Clothshouldbemadeofcotton.必须是棉布7.4.3 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。8 Takingoutofservice下模保养8.1 Forshortterm短期保养8.1.1 Switchoffhotrunnersystem.关掉热流道系统8.1.2 Spouttheinjectionunit.射空料管中的料8.1.3 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8.1.5 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。8.1.6 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。8.1.7 Useexhaustfunctionbycoolingcontrollerswhereitisavailable.用模温机的倒吸功能现将模具中的水排回。8.1.8 Blowthewateroutofthecoolingpipes(airpistol).使用气枪吹干水管8.1.9 Beforedemountthemoldithastocleancareful.下模之前仔细清理模具8.1.10 Userustinhibitortoprotectthemold,especiallythecavities.使用除锈剂保护模具，尤其是型腔8.2 Forlongterm(>3month)长期保养8.2.1 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8.2.2 Guideelementsormovingpartshavetobegreased.导向部件或移动部件须涂上润滑油8.2.3 Electricalplugshavetobecovered.电插头必须盖住8.2.4 Coolingconnectionshavetobecoveredwithplasticnipples.冷却水接头须用塑料封住9 Malfunction故障9.1 Incaseonecavityblocked堵穴情况9.1.1 Checktheheat.检查加热9.1.1 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9.1.3 Whenthereisakindofforeignsubstancekeepit,analyseitanddocumentit.当有异常的物质存在时，分析并在文件中记录9.1.4 Emptythehopperandcheckthematerial.清空储料筒并检查原料9.1.5 Spouttheinjectionunitfewtimes.-空射料筒中的原料几次9.1.6 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。9.2 Lossrangeoftolerancebyplasticparts产品超出公差范围9.2.1 Checktheinjectionprocesssetup(temperatures,times,velocities,pressures,etc.)检查工艺设定（温度，时间，速度，压力等）9.2.2 Checkcoolingsystem检查冷却系统9.3 Getanoisyscrew(injectionunit)螺杆噪音9.3.1 Assurethatthecylinderheathavethepropertemperature确认加热温度正常9.3.2 Assurethatthetraversetemperatureisnottoohigh确认下料口温度不是太高9.3.3 Observetheplasticizespeed观察塑化速度9.3.4 Doublecheckmaterialresignsforanypollutionandforeignmaterial再次检查原料粒子是否被污染或混入其它原料9.3.5 Checkthesizeofregranulate/repellits检查回料颗粒的尺寸9.3.6 Disassemblethescrewandcheckforanydefectandscratches.拆螺杆检查是否有划伤和其它缺陷9.4 Blackdots黑点9.4.1 Cleancompleteinjectionunit.清洁注塑单元9