heaco manual

HeaCo (Heat & Cool) Mold Temperature Control System

HeaCo Operating Manual

HeaCo Operating Manual

Unibell KoreaSep., 2007

HeaCo(Heat & Cool) Mold Temperature Control System

Notice and Safety

HeaCo system must be installed and operated by the trained specialist only who has full understanding on the unit operating manual.

HeaCo system has been made by the special control instruction as it should be operated at high temp. and high pressure. For delivery time, long distance transportation may effect a check-up points of piping material and connecting parts, for which installation & trial testing on the unit should be executed by the supplier’s technician.

Warning Symbols labeled in the machine

TOO HOT AREA

Unless handled by the specialist who read operating manual well, it may cause serious damage to body or skin burn by the high temp. Pay attention to this warning message.

Unless handled by the specialist who read operating manual well, it may cause serious damage to body due to high voltage pressure. Highly paying attention should be required.

In this high temp. liquid flow area, a pair of special glove for high temp. use is required. Highly paying attention is required against serious damage to body.

In this hot liquid flowing area, please pay a great attention for any damage to the body.

Unless handled by the specialist who read operating manual well, it may cause serious damage to body by the high temp. Pay attention to this warning message.

Safety Points

① This operating manual is prepared to use the system in safe way and maintenance so as to protect workers from danger. And this, please read it carefully and pay attention to any possible problems that may occur.

② This system should be handled by the specialist who has enough knowledge about plastic injection molding basic process as well as good understanding on our products.

③ Unless you keep safety instruction mentioned on this operating manual and safety regulations in the factory, it may cause the reason of serious accident in danger while operating or maintenance period.

④ A well trained specialist, who is permitted on safety and has good understanding on the manual, has to use and maintain the system.

⑤ This system is not subject to use for any other purpose instead of agreed condition.

⑥ Never touch the system with wet hands but use the glove that is to fit with hot temperature. Check it up.


Right Understanding on the Heat & Cool Process

Mold Tem

p. Curve

Control

Temp. down

Temp. up

Heating mediasupply

Coolingwater

Mold open Injection

heating

blowing

Seq. Eject, close & clamp Cooling

형개시작

Heatingfinished

Cooling heating Cooling

Heating mediasupply

Coolingwater

blowing

Injection start

Mold open InjectionEject, close & clamp Cooling

Mold Tem

p. Curve

Control

Temp. down

Temp. up

Heating mediasupply

Coolingwater

Mold open Injection

heating

blowing

Seq. Eject, close & clamp Cooling

형개시작

Heatingfinished

Cooling heating Cooling

Heating mediasupply

Coolingwater

blowing

Injection start

Mold open InjectionEject, close & clamp Cooling

For the plastic injection molding process, the mold temperature should be controlled in a uniform condition so as to produce stable end-products. The meaning of mold temperature control is to affect considerable molding conditions such as outward surface of the parts, electrical feature, residual stress, shrinkage rate, deformation and dimension stability. The temperature of the mold is used to be adjusted upon the specification of the plastic resin.In general, it is a common sense on the plastic injection mold that there are cooling water channels to cool down and heat up the temperature of the molds by means of oil or water energy to keep uniform temperature cycle. Depend on the specification of the plastic resin the working mold temperature shall be controlled within the range of 60℃ ~175℃. In this regard, the temperature of the mold should be lower about 10℃~15℃ than thermal deformation temperature of the plastic resin.In the meantime, there is a different and specific concept of mold temperature control in the Heat & Cool Process against existing control system so far. A series of this process is to go for injection after heating up the mold over the thermal transformation temperature and to extract the part after cooling down the mold temperature below the dimension transformation temperature (ejection possible temp.).

Heating & Cooling Cycle sequence

If such a heating and cooling process failed to be executed rapidly within the promised cycle time, there are serious productivity problems such as over cycle time, gas generation and degradation of the resin for its longer time to stay melted in the machine cylinder, which is actually a matter of difficult problem to be solved so far. Especially, some of the companies in Europe and the U.S. have been continuously studied for 20 years to find a way of quick heat-up and quick cool-down technology in order to put to practical use, but they made poor progress.


Right Understanding of HeaCo (Heat & Cool) process

Normal Molding Heat & Cool

Can Not Find Out Weld Line with Heat & Cool

In fact, if they could get the quick heat-up and quick cool-down technology, the progressive effect of the result shall be so much remarkable for the productivity, for it will be able to resolve the surface quality problem, which has been actually the most serious matter on the plastic injection molding process in case of exterior parts. By this technology, additional painting process will not be required any more, which will save the raw material cost and will get the high quality of the exterior parts as well.

Such defective points as weld-line, flow-mark, unbalance of surface gloss and transmission are essentials to do plastic injection molding. It is simple to explain the main reason why this kind of situation is essential to the molding parts. As for the injection molding, the molten resin is generally used to be filled into the cavity forming the fountain flow pattern. In review of the flow mechanism with a mold at the substantially lower temperature than the melting temperature, the melted resin at the front position is cooling down slowly and making frozen skinlayer. And the following plastic melted hot resin would enlargethe skin layer to be longer stream and consequently the skin layer could be gradually sticking to the inner surface of the cavity wall. At the same time, solidification is beginning and the skinlayer is being cooled down while it is in the long enlarged status, which will cause shear rate between the central flow-layer. The difference which is occurred between shear rate and cooling speed will cause the source of the defective quality. Especially, due to the specific character of plastic material, the melting viscosity of resin is quite rely on the temperature. And the flow length to decide volume of flowing comes under influence of thisdifference.

Normal molding Heat & Cool

PP+ long fiber Press Molding

Newly Generated for Heat & Cool System

Air-Steam generation system for Heating

Pump Station for Cooling

Control system

Operating Valves for heat and cool

Water purification system

Newly Generated for Heat & Cool System

Air-Steam generation system for Heating

Pump Station for Cooling

Control system

Operating Valves for heat and cool

Water purification system

Accordingly, we have reached to the understanding here that we would get remarkably quality improving effect if we could fill the melted hot plastic resin into the cavity after heating the skin core area of the mold up to the thermal deformation temperature, by which the flow length will be improved and the transmission to the shape of mold surface will become better.In order to realize Heat & Cool Technology in practice, there are three questions. Firstly, mold temperature should be efficiently heat up and cool down every cycle without being affected for productivity. The mold after doing required process (mold-open, ejectors forward, ejecting the parts and mold-close) must be in heat-up enough to wait for injection signal on time from the machine. While the injection machine is going to shot the hot melted plastic, the mold should not make the injection machine to delay the injection shot waiting for mold to be heat up. Therefore, mold heating and cooling process should be done rapidly within the cycle. Secondly, the mold itself should be improved further in order that it can be workable with such a quick heat-up and cool-down process.Finally, we have to mention the heat expansion problem that happens on the mold itself in case of continuous heat & cool operating for mass production provided that the above mentioned two conditions are optimized. There is a gas venting function equipped in the mold. But it is a problem when the gas venting lost its function.

Now we are going to introduce HeaCo System as the most efficient heating and cooling control system. This system has been developed to obtain maximum heating & cooling effectiveness by using the minimum energy.


Right Understanding On the HeaCo (Heat & Cool) Process



water spray

Air supply

Temp. SensorPress. sensor

Steam out

Water supply

water spray

Air supply

Temp. SensorPress. sensor

Steam out

Water supply

As a conventional heating & cooling method, existing industrial boilers have been used out. In this case, we could use the steam, the heating medium, obtained and saving after boiling the water. Otherwise, by means of a pressurized water heating method, we had to apply heat to water and compress the water over the water boiling point in order to get required heating medium. This heating medium was circulating inside the mold to heat up the mold.In this kind of boiling system, however, the temperature of heating medium is high but the pressure is low. As the pressure is low, flow speed is slow to pass the detailed heating hole equipped in the mold. In other words, this means the heating time should be longer. If you gave longer heating time to the machine until it can reach to the set temperature, we are afraid of the other mold area also to become hot, which may cause the source of bad dimension stability and deformation of the molding parts. Reviewing the conventional system, we had to face a problem by the different temperature between steam inlet and outlet in case of molding big sized plastic parts.Furthermore, once used steam could not be recycled but abandoned through the drainage line. The boiler should produce steam continuously and thus it requires huge amount of energy, which must be a demerit point of the boiler system.HeaCo System at the first in the world has developed to generate High Temperature and High Pressured steam by the minimum energy supply and to use it for thermal heating medium. The fundamental principle is to heat up the air inside the heating cylinder by means of electrical energy. And, we compress the water of normaltemperature in order to spray the compressed water through the specific nozzles. At the moment when the compressed water sprayed out through the nozzles, the molecular water particles touch with quick heated air and they are changing to be hot steam.

① Compressed air heated by heater band② Ambient temperature water supplied to the nozzle③ Water spraying into cylinder④ Air-Steam generated

⑤ Minute water particles and elements are captured by hot air

⑥ Atomized Water touched the inside wall of the cylinder changes into Air-Steam



New heating media (Air-Steam)Get the high pressure up to 30kgf/㎠Maintain High temperature more than 200℃

Use a natural phenomena with physical conceptUse Air, Water and ElectricityEnvironmentally friendly product

Most economic solution and Energy saving solutionLess maintenance cost than any other systemHigh efficiency (Short heating time)No steam supply piping arrangementMobile type

New heating media (Air-Steam)Get the high pressure up to 30kgf/㎠Maintain High temperature more than 200℃

Use a natural phenomena with physical conceptUse Air, Water and ElectricityEnvironmentally friendly product

Most economic solution and Energy saving solutionLess maintenance cost than any other systemHigh efficiency (Short heating time)No steam supply piping arrangementMobile type

It is a principle that hot air arrests the spraying out water particles and changed to be steam. There is a big energy consumption difference between water boiling and air heating, for the energy is proportioned to the mass of the medium to heat up. Also, in order to vaporize the water, it is much more advantageous to vaporize the water after splitting the water molecule as detailed particles. Especially, we are sure that there is a big energy difference in comparison it with a direct heating system after compress the water.

In view of the fundamental principle, there is a remarkable difference in our steam generating system compared with conventional boiler system. The quality of the steam generated by the principle is not possible to compare with the steam generate by the boiler.The conventional boiler has steam pressure up to 10kg/cm2 in general. The HeaCo System can make the steam pressure minimum 25kg/cm2 or more and will keep it in uniform condition.

For an application example, in case of LCD TV 42-57 inch, it is possible to heat up the mold temperature in 18~25 sec. from 65℃ to 120℃.Such a big sized molding part is produced in 1800~2500 ton injection molding machine. Mold heat up time up to set temperature in about 20 sec. is so wonderful, because it has done almost at the same time for mold-open, ejecting and mold-close within the cycle. There is no loss of cycle time. Of course, we start with a precondition that heating holes on the mold should be machined well to obtain the most efficient heating up. In brief, we are able to see in detail about the points to shorten the heating time and to improve the productivity as under.


Right Understanding on the HeaCo (Heat & Cool) Process

67″ front mask 1. Generally speaking, in order to minimize the heating time, the temperature of heating medium should high and the pressure also must be high. But, it is quite hard matter to increase the pressure. In order to heat up the temperature up to mold set temperature in a very short time, the temperature and pressure of the using medium are so important factors. And in order to obtain and distributing the regular temperature to overall skin-core of the mold, the instant flow speed of the supplying heating medium should be maximum fast.

2.Obtained heating medium temperature from the HeaCo System will keep basically 200℃ or higher and the pressure also start heating from 25kg/cm2 or more. Therefore, we are sure that this system is much more profitable than any other systems.

3. To make best use with high temperature and high pressure produced from the system, we have developed a unique drain control system on the steam outlet area and the effect has proved out.

Regarding the safety matter, at the moment that the pressure of steam is so high, safety problem can be considered. According to the basic rule of thermodynamics, if the steam has got discharged to the air and lost the energy out, i.e. if the steam pressure has got down to the atmospheric pressure, the temperature shall go down and then changed to water drops. In other words, in the restricted volume, such steam energy, which has got generated for simply heating up purpose, would not be enough to use.

Water supply & Steam Drainage system

Short heating time( same cycle time as normal molding)Total heating time < mold open + eject + mold closing time

Less energy consumption rateLow maintenance cost than any of normal boilersEasy installation( No steam supply piping arrangement)Easy to handle the machine

Heating up for the necessary surface onlyEasy to maintain dimensional stability than boilers-Short heating time = heat up for necessary surface only(HeaCo)

* Long heating time = heat up for surface with mold itself (Boilers) It means that it is not possible to keep a necessary dimensional stabilities and to be avoided from the warpage due to temperature deviation for 60” TV front mask .

Short heating time( same cycle time as normal molding)Total heating time < mold open + eject + mold closing time

Less energy consumption rateLow maintenance cost than any of normal boilersEasy installation( No steam supply piping arrangement)Easy to handle the machine

Heating up for the necessary surface onlyEasy to maintain dimensional stability than boilers-Short heating time = heat up for necessary surface only(HeaCo)

* Long heating time = heat up for surface with mold itself (Boilers) It means that it is not possible to keep a necessary dimensional stabilities and to be avoided from the warpage due to temperature deviation for 60” TV front mask .

For example, in case of a pressurized water heating method, you have to keep enormous energy due to the weight of water, especially after heating up, you have to operate the water return circulation system (water should be returned definitely in order to minimize the energy.). But when you have a leakage problem on it, all water stored inside should be discharged for repair, which is a demerit point.With our HeaCo system, after heating up process, we can discharge all out used steam through drain lines, but we can generate steam continuously enough to use by means of low energy consumption, which is a special point.

In view of energy consumption point, HeaCo System is energy saving system without doubt. HeaCo System takes air to heat up and then spray water to get the steam. Meantime, steam boiler takes oil or town gas energy to heat up the water for steam generating. In a short comparison with two systems, we can see remarkable difference for energy consumption. In addition, as far as the normal boiler system has to move the energy to the required place through steam pipe, high energy consumption is required and heating time is various upon the pressure fluctuation. Such a demerit points are well cleared out and resolved in HeaCoSystem which has been developed and produced by Unibell Co., Ltd.


Right Understanding on the HeaCo (Heat & Cool) Process


1. General Specification

3.2

3.2

87.5

Cooling pump

Steam pump

100Controller

500HeaCo Main body

1100

1000 x 1000 x 1700Water purifier

1500/100

360/25Steam

450 x 500 x 1600

820 x 1850 x 1750HeaCo Main body

DataunitDescriptions

16 inlet/outletEASteam Outlet

Heater

kWElectric Power

Waterpsi/barMax. pressure

250℃Max. temperature

Controller

mmDimension(W x L X H)

Water purifier

KgWeight

3.0 tons per dayConsumption rate

Below 300ppm

Minimum 4 kgf/㎠*At loading of water purifier, it must be above 3 kgf/㎠

Quality Level

Pressure

----City-water

Min. 6 kgf/㎠Compressed air


2. Utilities Specifications

Quality ★Use a clean water without any particles and below 300ppm water quality★ Install an additional “Pre-filters”

1 /2” freely flow without back-flow

3/4”

Drain Line

Flow rateCity Water

Supply

Supply Pressure

Single phase 15A Consent

150 liter/min

Min. 3.0~5.0 kgf/㎠

3 wires + groundCables

Min. 175 ABaker size

★ If voltage fluctuation over +/- 5%AVR required

Min. 70 Square

1 ~ 2”

2”

Outlet★ Use a clean water with no minerals for no-depositing of a scale★ Install an additional “line-filter” if possible a particles may mixQuality

InletPiping size

200 liter/minFlow rate

Min. 2.0~3.0 kgf/㎠

Power cable Size

HeaCo

1000 cc /cycle( *exclusive air blowing)

Min. 6 kgf/㎠Pressure

Inlet

Water Purifier

DataDescriptions

ConsumptionCompressed air

Piping size

Electric Power Connection

Supply Pressure

Cooling water Supply


2. Utilities Specifications

As mold temperature heat up to set temp., supplying the signal to IMM.IMM start injection by the signal.

Interface SignalOutput Signal to

IMM

Injection start , Cable No. X035

Supply output of free-contact pulse only★Injection start interruption

until get the output signal

Supply output of free-contact pulse onlyCooling start signal

Mold opening start , Cable No. X034

Supply output of free-contact pulse only

DataDescriptions

Heating start signalInterface SignalInput Signal to

HeaCo


3. Looks


3. Looks

Interface signalto IMM

S1

Steam, Cooling water & Air blowsupply line

Steam, Cooling Water & Air blowPurge line

Purge Manifold

Thermocoupleconnection line

Additional SteamDrainage


4. Transportation

When you are going to move the HeaCo unit to anywhere, please read on the application of casters on the manual carefully before moving it out.Do not handle the unit using an overhand crane but please use a lift truck.

Regarding the packing materials for the unit before shipment, it should be disposed in accordance with the current laws.

5. Installation

Outdoor installation is prohibited . The unit must be installed in the room.① Provide minimum 1 meter distance from the sides of unit for proper service and maintenance.② After making a decision of the location, the level of the unit is to be adjusted by the height adjustment and then it

will be locked. ③ Make sure that there are 4 sets of height adjusters and please lock them up once again after level adjustment.


6. Utilities Connection ① Cooling water supply:

In view of Steam Mold system, cooling water supply takes an important role. If it is not enough to supply the cooling water in volume, at the first, the Cooling Water Pump in HeaCo system can be damaged so easily as it will go for overload working. Cooling water will receive pressure to be sent into the mold for cooling process and it will affect to the cooling time. Without supplying enough water, the cooling time shall be longer.In case of bad quality of cooling water, too many calcium and of other substances included, this calcium material will prevent air driven valve operation from the normal operating, which will cause shorter life than normal guaranteed life. You may have to frequently clean the steam line/cooling line for the scale elimination. Accordingly, to manage the water quality thoroughly could be the best way for the machine to keep longer life and to protect it from any defective factors.

② Main Electric power connection:HeaCo system has considerable capacity of heater and therefore careful preparation is required

according to the specification mentioned in this operating manual. Especially, it is noted that we use ceramic heater band on the heater, which has specific function to draw up the electric power for an instant in order to get heat up. If there are less electric capacity installed, it may cause overload heater and shorten the life, by which electrical problems can be occurred. Enough electric power supply must be provided all the time.

③ City-Water supply: In the HeaCo system, City-Water is used to get the steam. City-Water will be linked to Water

Purifier to be purified up to around 10ppm degree of purity. This purified water shall be provided to HeaCo system. Here, the water pressure and water volume to be supplied will be very important factors. Less water pressure and water volume will cause abnormal operation of the pump in the water purifier and will bring short life as well. Also, in case of water drainage, on the water purifier, the water should be drained without any pressure. By the way, if there is still holding pressure remained backward, it is not possible to drain out completely, for which filter life on the water purifier might be shortened. If water quality is not in a good condition, place pre-treatment filter or water softener before installing water purifier so as to provide pure water into the water purifier and as a result to keep long life of the precise water purifier’s filter.


6. Utilities Connection

Additional Steam Drain Line.. Freely flow to factory main drain must be no-back flow !!!!!

Compressed Air supply

Additional Steam Drainage 3”

2” 1”

Cooling water In

Cooling water out (Drainage)

1/2”3/4”

Waste water Drain line

City water supplymin.3 kg/㎠

1/2”

3/4”

1/2”

Purge- Manifold

Water purifier


6 Utilities Connection Information

Cooling water In & Out for mold cooling Hose connection In 2″, Out 1″

Minimum cooling water pressure min. 2~3 kg/㎠Temperature below 23℃

Purified water supply In line from Water purifier½″ one-touch Air-hose

Steam drainline of Safety-valve 3/8″ High temp. & pressure resistant hose connectionConnecting to “Steam drain/purge line”

Air-supply line for mold air blowing 3/4″ hose connection


6. Utilities Connection Information

Interface signalWith IMM

Interface Signal ConnectionIt is to be supplied only for pulse signals from IMM, the contacts are volt free (dry contact)

INPUT SIGNAL TO HEACOHeating start : X034 & N24VSignal at the start of mold openCooling start : X035 & N24VSignal at the start of Injection

OUTPUT SIGNAL FROM HEACO TO IMM 014 & COMMAs mold temperature is reaching to the set temperature, HeaCo supply the signal to IMMWhen IMM get the signal from HEACO for heating finished, this interlocks IMM starting injection at the time of mold temperature reached.

Connect tothe Purge- Manifold


• In order to set HeaCo system for normal operating condition, the following signals are required to receive from the Injection

molding machine. For a connection each other, we need signals form IMM as follows.

• In general, two signals must be given to HeaCo. for Heat-up start, Mold open, Cooling start and Injection start.

Heat-up start signal (X034 and N24V)At the AUTO mode, when the mold open start relay pulse works, it means heat-up start signal working. When heat-up start

delay time is counting on until the delay time is finished, it means steam will be supplied into the mold for mold heat up

starting.

Heat-up complete OUTPUT signal (014 and COMM.)When the mold temperature comes up to the set temperature, heat-up process will be stopped. And then heat-up complete

signal shall be informed to the injection machine. After receiving this signal, the IMM will start injection molding. Likewise, we

need interference for injection start. Injection should be started after receiving the heat-up complete signal from HeaCo

system.

Cooling start signal (X035 and N24V)Cooling cycle will be started after receiving the Injection start signal or injection complete signal. Set delay time will be

counted and after passing the delay time, cooling water will be supplied for mold cooling. .

When heat-up start or cooling start relay signal is given to the system, you can check the interlock signal connection situation so easily on the MENU bar of the screen. Heating lamp is ON while the mold is heating up and Cooling lamp is ON while the mold is cooling down.



Steam On/Off Valve

MOLDDrain On/Off Valve

Steam Out Line

Cooling On/Off Valve

CoolingPump

On/Off valve

Airblow Valve

• Steam drainage line will be installed to drain out the air steam,

cooling water, remaining water and compressed air, which had been

supplied into the mold through HeaCo system.

★ Usually, it is easy to neglect installing separate steam drain line, because of simple thinking that steam in high pressure could be out easily through cooling water drain line. However, it is not true. At the moment when steam in high pressure is touched with water, the temperature will drop down to normal temp. and the pressure also shall drop to zero for not flowing out. Without separate steam line or output drain line of load-free, you won’t get heat-up properly. Heating time will be much longer, because steam is not possible to flow out. Steam drain line will be installed to anti-operator side by means of cooling water drain line, however it should have no interference of the pressure or back pressure. Best way is to install the separate drain line. From the drain manifold to the steam drain line, 1 inch high pressure/high temperature hydraulic hose shall be fixed conveniently, of which length shall be 2 meter in general from the lower side of IMM fixed platen to the entrance of steam drain line.


IN MANIFOLD

OUT MANIFOLD


7. Example of Closed Water Supply Layout


10. Example of City-water supply

Water tank

Water Purifier

City-waterSupply line

1” Piping 1” Piping 1” Piping

Pre-filter Carbon Filter

Water Purifier

3/4” Piping

Pump Specification


8. Check Points of the connections

Air vent bolt

① Purified water (below 15.0ppm) by the water purifier shall be connected to the water supply line. This water line shall be

connected to water compressor supply line.

② Be sure to connect with clean out treated compressed air. Compressed air shall be connected to both air blow air-line and valve

driving air-line.

③ Connect cooling water line to water supply line and drainage line.

④ Connect main power cord.

⑤ Connect steam drainage line.

⑥ Connect the line which is located backward to the safety valve with Steam Drainage Line.

⑦ Connect the supply hose to the IN MANIFOLD and the MOLD. Connect the drain hose to OUT MANIFOLD and the MOLD.

After checking all the connections upon the above procedure, please make sure the following points.

① Check the purity of the water on the water purifier. By the purity sensing gauge equipped with the water purifier, please check

the value of the purity. It should be maintained lower than 15.0 ppm in order to supply the water into HeaCo system.

② Open the air supply manual ball valve, Cooling water supply valve and drain manual ball valve. Turn ON the main power switch.

③ Check out the direction of the cooling pump motor rotation. The rotating direction should follow the mark mentioned on the

pump (clockwise). Also, please open air drain valve a little which are located on the below of the pump and on the upside of the

pump. When the air drained out completely and water drained, then please close up the valve lightly.


9. Installation Check Sheet

heaco manual

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