Guidelines for Preventing Stoppages on a Pad Printing Machine Guidelines For preventing stoppages on a pad printing machine Kimberly Busuttil University of Malta i
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guidelines For preventing stoppages on a pad printing machi...
University of Malta: Final Year Project 1 Guidelines for Preventing Stoppages on a Pad Printing Machine Author: Kimberly Busuttil Edition Number: 1.0 Edition Date: 05/ 2016 Intended for: General Use: must use injection moulded parts as the input Kimberly Busuttil ii
University of Malta  Final Year Project  1 Guidelines for Preventing Stoppages on a Pad Printing Machine  Author   Kimberl...
Contents Guidelines for Preventing Stoppages on a Pad Printing Machine ........................................... ii 1.1 Guidelines for when Machine Stops at Vibratory Conveyor ....................................... 1 Guideline G1 ....................................................................................................................... 1 Guideline G2 ....................................................................................................................... 2 Guideline G3 ....................................................................................................................... 3 1.2 Guidelines for when Machine Stops at the Infeed ..................................................... 4 Guideline G4 ....................................................................................................................... 4 Guideline G5 ....................................................................................................................... 5 Guideline G6 ....................................................................................................................... 6 Guideline G7 ....................................................................................................................... 7 Guideline G8 ....................................................................................................................... 8 1.3 Guidelines for when the Machine stops at the Index Table....................................... 9 Guideline G9 ....................................................................................................................... 9 Guideline G10 ................................................................................................................... 11 Kimberly Busuttil iii
Contents Guidelines for Preventing Stoppages on a Pad Printing Machine ........................................... ii 1.1 ...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guidelines for when Machine Stops at Vibratory Conveyor Guideline G1 G1. IF machine stops due to congestion at vibratory conveyor AND because of flash defects THEN avoid formation of flash defects by considering: i. Decreasing the injection time whilst acknowledging the shot size ii. Decreasing the injection pressure iii. Decreasing the melt temperature by lowering the barrel temperature iv. Changing the mould tool parameters principally: o Increasing the mould tool clamping force o Arranging any misalignments between the mould halves o Increasing the mould temperature o Repairing or replacing mould tools with defects Side view Side view Rail transferring parts Rail transferring parts Parts move into Cylinder Parts move into Cylinder Parts without flash defects pass through Parts with flash defects lose balance and fall, the vibratory conveyor smoothly jamming the rest of the parts Situations for G1 Kimberly Busuttil 1
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guidelines for when Machine Stops at Vibratory Conveyor  Gu...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G2 G2. IF machine stops due to congestion at vibratory conveyor AND because of flash defects THEN avoid formation of flash defects by considering: i. Decreasing the injection time whilst acknowledging the shot size ii. Decreasing the injection pressure iii. Decreasing the melt temperature by lowering the barrel temperature iv. Changing the mould tool parameters principally: o Increasing the mould tool clamping force o Arranging any misalignments between the mould halves o Increasing the mould temperature o Repairing or replacing mould tools with defects Plan view Plan view Vibratory conveyor transferring parts Vibratory conveyor transferring parts Parts without side flash pass through the Parts with side flash get stuck due to larger vibratory conveyor smoothly widths that are caused by side flash Situations for G2 Kimberly Busuttil 2
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G2  G2. IF machine stops due to congestion at vib...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G3 G3. IF machine stops due to congestion at vibratory conveyor AND because of short shots THEN avoid formation of short shots by considering: i. Increasing the injection time whilst acknowledging the shot size ii. Increasing the injection pressure iii. Increasing the melt temperature by increasing the barrel temperature iv. Changing mould tool parameters principally: o Increasing the gate temperature through the hot runner parameters o Increasing the mould temperature o Repairing or replacing mould tools with defects Side view Side view Rail transferring parts Rail transferring parts Parts move into Cylinder Parts move into Cylinder Parts that are not short injected pass Parts that are short injected lose balance and through the vibratory conveyor smoothly fall, jamming the rest of the parts Situations for G3 Kimberly Busuttil 3
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G3  G3. IF machine stops due to congestion at vib...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guidelines for when Machine Stops at the Infeed Guideline G4 G4. IF machine stops at the infeed AND because of flash defects THEN avoid formation of flash defects by considering: i. Decreasing the injection time whilst acknowledging the shot size ii. Decreasing the injection pressure iii. Decreasing the melt temperature by lowering the barrel temperature iv. Changing the mould tool parameters principally: o Increasing the mould tool clamping force o Arranging any misalignments between the mould halves o Decreasing the mould temperature o Repairing or replacing mould tools with defects Front view Front view In feed at index table Parts without flash balance and enter the jig Parts with flash stand in an angled position smoothly and fail to enter the jig Situations for G4 Kimberly Busuttil 4
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guidelines for when Machine Stops at the Infeed  Guideline ...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G5 G5. IF machine stops at the infeed AND because of long injection points THEN avoid formation of long injection points by repairing or replacing mould tools with wear at the gates of the cavities Front view Front view In feed at index table Parts that have no injection point enter the When a long injection point is present, it jig smoothly interferes with the jig at infeed Situations for G5 Kimberly Busuttil 5
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G5  G5. IF machine stops at the infeed AND becaus...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G6 G6. IF machine stops at the infeed AND because of short shots THEN avoid formation of short shots by considering: i. Increasing the injection time whilst acknowledging the shot size ii. Increasing the injection pressure iii. Increasing the melt temperature by increasing the barrel temperature iv. Changing mould tool parameters principally: o Increasing the gate temperature through the hot runner parameters o Increasing the mould temperature o Repairing or replacing mould tools with defects Front view Front view In feed at index table Parts that are properly formed enter the jig Short injected parts are incapable of smoothly remaining in an upright position and hence cannot enter the jig Situations for G6 Kimberly Busuttil 6
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G6  G6. IF machine stops at the infeed AND becaus...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G7 G7. IF machine stops at the infeed AND because of warpage THEN avoid formation of warped parts by increasing the cooling time Front view Front view In feed at index table Parts that are properly formed enter the jig Warped parts cannot enter the jig due to the smoothly deformed shape which interferes with the jig Situations for G7 Kimberly Busuttil 7
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G7  G7. IF machine stops at the infeed AND becaus...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G8 G8. IF machine stops at the infeed AND because of a loose jig or inaccurate part dimensions THEN avoid parts falling out of jig by considering: i. Confirming that parts dimensions are the same by always using parts from the same injection moulding machine ii. Checking the jig on the vertical index table by o Removing excessive debris o Confirming that all its components are intact specifically the spring Front view Front view 2 3 Motor 2 A. Motor 4 1 B. 3 4 1 In feed at index table After the standard part is fed into the jig, it is moved up in clockwise direction Front view Front view 2 3 Motor 2 A. Motor 4 1 B. 3 4 1 In feed at index table When the parts are inconsistent in size, the parts fall out Situations for G8 Kimberly Busuttil 8
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G8  G8. IF machine stops at the infeed AND becaus...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guidelines for when the Machine stops at the Vertical Index Table Guideline G9 G9. IF machine stops due to a stoppage on the vertical index table AND due to incorrect turning at motor [detected by sensor] THEN avoid incorrect infeed by considering: i. Changing the parameter settings including o Vibration amplitude o Infeed speed o Infeed distance ii. Confirming that parts dimensions are the same by always using parts from the same injection moulding machine iii. Checking that the machine’s components are not faulty principally: o Any misalignments that may be present between the end effecter and the vertical index table o The motor on the index table o The jig on the index table by Kimberly Busuttil  Removing excessive debris  Confirming that all its components are intact specifically the spring 9
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guidelines for when the Machine stops at the Vertical Index...
Guidelines for Preventing Stoppages on a Pad Printing Machine Sensor Front view Sensor Front view 1 2 Motor 1 A. Motor 3 4 B. 2 3 4 Motor turns part in correct position Sensor Front view Sensor Front view 2 Motor 1 A. 21 3 Motor 4 4 B. 2 3 Sensor detects incorrect position, stopping the machine Situations for G9 Kimberly Busuttil 10
Guidelines for Preventing Stoppages on a Pad Printing Machine  Sensor  Front view  Sensor  Front view 1  2  Motor  1  A.  ...
Guidelines for Preventing Stoppages on a Pad Printing Machine Guideline G10 G10. IF machine stops due to a stoppage on the vertical index table AND due to incorrect turning at motor [not detected by sensor] THEN avoid incorrect functioning of the sensor by considering: i. Correcting the position of the sensor ii. Checking if the sensor needs servicing or repairing Front view Front view Sensor Sensor 1 1 Motor 1 22 A. 4 Motor 2 B. 4 3 3 3 Sensor detects incorrect position and stops at the sensor, not allowing the vertical index table to rotate any further Front view Front view Sensor Sensor 4 1 Motor 4 A. Motor 2 3 B. 1 2 3 Sensor does not detect the incorrect position and so the jig on the vertical index table attempts to feed the part onto another jig Situations for G10 Kimberly Busuttil 11
Guidelines for Preventing Stoppages on a Pad Printing Machine  Guideline G10  G10. IF machine stops due to a stoppage on t...