Since the release of Qiaotian one-stop automatic mould changing solution, Qiaomei has received a lot of product inquiries about automatic mould changing: no bolts, no hydraulics, is it really safe to change the mould magnetically? Next, the bridge sister will take you into the automatic mould changing system through two customer cases.

01 A mould factory 2400T magnetic mould change project

The status quo of a mould factory is to use the pressure plate to change the mould, relying on manual operation, each set of moulds need to load and unload 16 sets of high-strength bolts, a single change of the mould takes up to 1 hour, and due to the difference in the specifications of the moulds, you need to adjust the pressure plate frequently, resulting in the fluctuation of the positioning accuracy of ± 0.1mm, the more serious thing is that the pipeline connection needs to be synchronized with the operation of the 5 technicians, the rate of misplugging is as high as 5%.

According to the customer's actual production needs, Qiaoda Intelligence is equipped with an automatic mould change solution consisting of magnetic plates and energy combination module products.

First of all, the magnetic plate adopts high permeability alloy magnetic pole matrix to achieve 2400T-class moulds with 3-second high-speed charging/demagnetising, magnetic suction density up to 16Kgf/cm2, adaptable to ±50mm thickness tolerance, completely free from the limitations of platen specifications. The magnetic module adopts hybrid technology of electro-permanent magnetism, which can maintain the mould locking state in case of sudden power failure (without external power supply), avoiding the risk of mould falling.

In addition, the system has a built-in 64-zone pressure sensing network, which displays the distribution of clamping force and safety coefficient in real time, and automatically calibrates the risk of off-loading, preventing the deformation of moulds due to uneven force and the risk of hydraulic leakage.

Considering the customer piping connection problem, Hashida team highly integrates water, oil, gas, electricity and other energy sources, i.e. one time plugging and unplugging completes all the connectors of the whole mould, and a single person completes all the media connection in 3 seconds. At the design level, the modular plugs and guide pins are precisely matched to eliminate misplugging and leakage, and avoid downtime loss due to interface error.

After the application of this solution, the number of mould change operators was reduced from 5 to 1, and the unplanned downtime caused by mould change failure was reduced by 95%.

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02 110T magnetic mould change project for a medical products factory

The status quo of a medical products unit is that there are as many as 4 kinds of moulds switching in a single station, and the average mould switching time is 1-2 times per day, and the time for each mould change is 40-60 min. The traditional mould clamping method is not only inefficient, but also produces debris due to metal friction, which pollutes the production environment. Meanwhile, the mechanical constraints of the guide columns in the bolt locking method will limit the free expansion of the template, resulting in the risk of distortion and misalignment of the mould due to the difference in thermal expansion, which affects the accuracy of the product.

According to the customer's actual production needs, Qiaoda Intelligence adopts the magnetic adsorption automatic mould change solution.

Firstly, the mould is adsorbed by the magnetic plate, non-mechanical clamping, and the customer's problem of environmental pollution due to metal debris is completely solved. At the same time, the permanent magnet adsorption force is automatically adjusted with temperature, avoiding stress concentration and allowing the mould to expand freely without customised fixtures or adjusting the mechanical structure, solving the customer's problem of mould misalignment due to temperature difference deformation caused by traditional bolt locking.

In terms of product safety, customers can view the adsorption force curve, mould position, temperature and other parameters in real time through the HMI interface, and in case of abnormality, the system automatically alarms and triggers the secondary magnetisation to ensure that the safety coefficient is up to standard. In addition, the system is equipped with redundant magnetic circuit design, which can still maintain more than 80% of the adsorption force in case of single point failure. This ensures that there is no loss of magnetism in case of power failure, avoiding accidental dislodgement of moulds and ensuring production continuity.

After the application of the solution, the product operation without human intervention, the system automatically optimises the clamping parameters, a key to achieve the adsorption and release of the mould, the mould change time from 40-60min to 3min. positioning error from ± 1mm to ± 0.01mm, product accuracy increased by 90%.

See here, the bridge sister reply to the beginning of the question: no bolts, no hydraulic pressure, magnetic mould change is really safe! Want more information about ‘Hashida automatic mould change system’ products, background send ‘mould change’ two words, you can get.