Practical values of melt correction factor for use incalculation of shot weight for some commonplastics
Shot weight = melt correction factor x swept volume in cc
The melt correction factor takes into account the change involume at process temperature and also includes a factor forthe flow characteristics of the shut off device on the end of thescrew
HD-PE 0.75
LD-PE 0.73
PP 0.73
PS 0.91
SB 0.91
ABS 0.91
SAN 0.91
PA 0.93
PA 6 + 30% GF 1.14
PC 0.97
POM 1.15
PET 1.08
PBT 1.08
CA 1.03
CAB 0.98
PVC - s 1.05
PVC - r 1.15
Thermoset - PF 0.96
PC / ABS alloy 0.94
PMMA 0.97
Material Melt Correction Factor
PP
M/2
00
7/0
8/r
ev.0
1
Bangalore
Chandigarh
Chennai
Coimbatore
38, Cubbon Road, P.O. Box 5098,Bangalore 560 001Tel : 080-25020100/0236, Fax : 080-25536397e-mail : [email protected]
32, Sector 26-D, Madhya Marg,P.O.Box 14, Chandigarh -160 019.Tel : 0172-4646846, Fax : 0172-4646802e-mail : [email protected]
10, Club House Road, Anna Salai,Chennai 600 002Tel : 044-28462034, Fax : 044-28462088/2152e-mail : [email protected]
123, Appuswamy Road,Coimbatore 641 045Tel : 0422-2311562, Fax : 0422-2313881e-mail : [email protected]
SALES & CUSTOMER SUPPORT CENTRES :
Hyderabad
Kolkata
Mumbai
New Delhi
2nd & 3rd Floor, SUMMIT,5-10-188/2,Hill Fort Road, Hyderabad 500 004Tel : 040-66720000, Fax : 040-23242356e-mail : [email protected]
3B, Shakespeare Sarani,Kolkata 700 071Tel : 033-22825138,Fax : 033-22827587 / 22821025e-mail : [email protected]
EPC Block, 5th Floor, ‘A’ Wing,Gate No.1, Powai West, Mumbai 400 072Tel : 022-67053580/3688/1147Fax : 022-67051309e-mail : [email protected]
32, Sivaji Marg, P.O. Box 6223,New Delhi 110 015Tel : 011-41419585/87, Fax : 011-41419518/9600e-mail : [email protected]
Pune
Vapi
Vadodra
191/1, Dhole Patil Road,P.O. Box 119, Pune 411 001Tel : 020-26113557, 56033355 Fax : 020-26113557e-mail : [email protected]
19/23, Mohid Towers, Vapi-Daman Road,Chala, Vapi 396 195Cell : 93273 74710e-mail : [email protected]
Radhadaya Complex, Near Charotar SocietyOld Padra Road, Vadodara 390 015Tel : 0265-2343238, Fax : 0265 2336184e-mail : [email protected]
L&T - Demag Plastics Machinery LimitedChembarambakkamOff - Chennai - Bangalore HighwayP.O. Box No. 5Chennai - 602 103Phone : +91-44-26812000, Fax : +91-44-26810303E-mail: [email protected]
MANUFACTURED BY HEAD OFFICE
Plastics Processing Machinery, LTM Business Unit
Mount Poonamallee RoadManapakkam, Chennai 600 089. India.
Tel: +91-44-22491932 / 22497360Fax: +91-44-22492471
E-mail: [email protected]@ltmindia.com
LARSEN & TOUBRO LIMITED
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All manifold blocks & valves mounted close to the actuators forfaster responseOil tank with large opening for cleaningPre heating circuit for hydraulic oilOil temperature regulated with temperature indicationConnectors for external oil filtration during production (bye passfiltration)Automatic monitoring of oil filter clogging with advance warning andread outPump unit switched off if minimum oil level is reached or if the oilfilter is100% blockedProduction stopped if oil temperature exceeds maximum valueHigh pressure filter with clogging indicationExternal oil coolerDigital principle of control for speed and pressure for consistent andreliable performanceFast responding and non-aging catridge logic elementsFast responding hydraulic door safety interlockEnergy saving pump switch off feature in case of idle running
Intelligent operator terminal with large multi colour LCD displayand alpha numeric key board (10.5")Easy setting of parameters through graphics using mouse wheel3.5” disc drive for loading Ergocontrol and PLC software and also forstoring machine setting dataCAN bus as field bus linking the Ergocontrol and machinecontrollersPosition measuring system for moving platen, ejector, and screwtravelSetpoint input on the Ergocontrol in physical values (bar, cc,mm/sec, screw rpm) or speeds for mould, ejector, core puller andnozzle as a percentage of maximum valueGraphics supported input of set point profiles for injection speed,follow up pressure, back pressure and screw speed as an alternativeto entry of numerical values2 screens free for entry of general data (set up information)Continuous Process control via monitoring of important processparameters with selectable tolerance bandMoulding counter preselection with automatic switch off featureShift and batch production counters with rejection monitoringFault diagnostics in the event of machine malfunction or operatorerror with plain text messages and recording of source of errorAutomatic switch off mould cooling in the event of fault in the cyclePrinter interface (centronics) through parallel portPDS Process data acquisition PDE with statistics and graphics
Measurement of cycle, injection, plasticising and mould protectiontimesRegulated power supply 24V DC for controls and actuatorsSet of electrical outlet- Single Æ (1x 10 A) & 3 Æ (1x16 A)Socket for printerMulti level password for preventing tampering of parametersSmart card reader for preventing unauthorised accessFlash lamp /Acoustics alarmHot runner controlled integrated (upto 16 zones)Flexible motion sequences for cores and ejectorsDigital setting of all times,setting range in secondsFunction wise layout of pages(screens) and ergonomical display ofvarious process parameters/data in clear textHeater current display device (upto IU 900 only)PID control loops and semiconductor relays for cylinder heatingsystemSelf Optimising PID control loops and semiconductor relays forcylinder heating systemMain voltage 415V/3ph/50Hz, control voltage 24VDC/220VInternal storage of upto 60 mould set programmersInjection speed settable in mm/sec and pressure settable in barInjecton speed settable in 63 steps and pressure settable in 127stepsPC connectivity for additional storage of mould catalogueSwitch on programme for oil preheating and cylinder heating
Controls
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Energy indication on operator panelSPC and CPk with graphical displayMachine troubleshooting module indicating clear direction toresolve problemsHot runner shut off device (pneumatic/hydraulic)Remote access of control pagesDown time logStrat up module for automatic selection of process parameters(Ergostart)Insulated heater bandsAuto switch off programme - purging w/o hopper shutoffLanguage optionsProgrammable automatic switch-off matrixNetworking of machines
Guarded machine enclosure with space for protruding moulds andperipheral connectionsOne piece machine bed (upto 350)Safety equipment as per EN 201Flexible machine support with anti vibration mountsTotal preventive maintenenceThree way access for easy part removalComplete cover on the Injection unit front sideMould clamps - 8 numbersSeparate oil filter for fine straining (Bypass filtration); integrated inthe machineThree color lamp (only in LNC)
Single phase preventorConnection for additional heater band - only plug will be with themachine32 pole signal interface in accordance with VDMA for robots/spruepicker (E12)Euromap 67 interfaceRotating core interfaceMould protection by monitoring ejector back sensing using limitswitch (1 no.) in mouldInterface for ejector limit switch(2 nos) in the mouldSensor interface for monitoring drop of mountings with photocelloptionFreely programmable I/O's (Max.2 I/O-LNC5,6 I/O -Ergo)3 Stage start up programmeAutomatic printer programmeThermal printerInterface for indexing conveyor/floating contactBlending unit interfaceChiller/peripheral fault interfaceAmendment report logInterface with gas assisted mouldingInterface for quick mould changeInterface for cavity pressure sensor - upto 2 channelsInterface for add. nozzle heater band (plug only)Interface for slide core safety controlInterface upto 4 temperature control units, 3 point controller -Outputs for heating and coolingCAN interface for temperature control device - upto 2 circuitsInterface mould temperature display on IBED; upto 2 - mouldcircuitsThermal printer integrated in ErgocontrolTPM programHelp MenuProcess data storage (on floppy in ergocontrol/download in excelformat in LNC)Flexible motion sequence - CU-IU (core and ejector movement, IU)Insert loading sequenceProcess trouble shooting (Ergoexpert)Injection compression sequenceBreathing sequence
General
Functions/Interfaces
√ ●- Standard - OptionNA - Not Available NEC - No extra cost, ALT - Alternative Equipment
40 - 650
FEATURESLNC5 ERGOClamping unit
Injection Unit
Computer optimised 5-point twin toggle system, for fast, smoothplaten movement and even distribution of clamp forceMoving platen supported on the machine bed by anti-friction rollerbearingsMould opening and ejector forward with safety guard open /closedpositionMould mounting dimensions as per Euromap - Threaded holesupto 300T and T-slot from 350T (with ejector holes on Movingplaten for Euromap/JIS)Add-on T-slot plates upto 150T,Integral T slot 180 T to 300TMould Mounting dimensions as per DIN/SPI standardsDrill hole pattern for robot/sprue pickerRear safety guard suitable for robot/sprue pickerHard chrome plated tie barsToggle bearings oil/grease lubricated: lubrication signalscomputer optimised under adaptive controlMotorised mould height adjustment through sun & planetary gearmechanismConsistent mould open stop position using stroke adjustmentmechanism in cylinder set manuallyConsistent mould open stop position using mould openproportional valveClosed loop clamp force control on control panel with indicationand correction every cycle, settableClosing and opening speeds independently set: eachprogrammable in 3 stagesRegenerative circuit in mould closing for higher speedsLow pressure mould safety, settableMould protection with stroke dependent change over with timemonitoring and repeat of a clamping cycle aborted in the protectedrangeCentral hydraulic ejector with multiple stroke features and fastcoupling; pressure and speed independently set in both directions,ejector speed programmable in 2 stagesMould cooling water switch off in case of interruption of cycle, withsettable timerWater battery - 4 fold upto 250T; 6 fold above 250THydraulic ejector parallel to mould movement with speed andpressure manually adjustableShort and long stroke ejector, freely programmableMulti point ejector plate as per EuromapMultipoint ejector plate as per JISWater battery - 6 / 8 / 12 fold1,2,3 or 4 pneumatic valves (5/2 type)freely programmableCore pulling control for 1,2,3 or 4 hydraulic/pneumatic coresindependently programmable for sequential operation or parelleloperationHydraulic ejector/core parellel to mould opening with independentcontrol of speed and pressure through proportional valve; ejectorand core with serial movement to each otherGood/bad parts selector,via continous process controlAutomatic mould height adjustment through proximity switch(upto 350T)Automatic mould height adjustment through Linear potFoolproof hydraulical and electrical interlocks for safety gatesStainless Steel Discharge chute upto 250 TElevated base for clean roomAdditional 4/6/8/10/12 water manifold with Original Italy makeballvalve control with Stainless steel SS304 .Pneumatic operated safety door
Central Ejector rod (as per m/c manual )Connections for 2 core pull controls at fixed platenNonreturn valve of ejector (for moulds with spring loaded ejectors)Multipoint Ejector Rods (M12 Internal threads on one end)
Injection unit with torque-free nozzle contact with 2 cylinde
Injection unit speed of nozzle advance and retractionprogrammable in 2 stagesNozzle contact pressure programmable
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Injection speed, follow up pressure and screw speed controlled byfast response DFE pumpDirect screw drive by hydraulic motor 1 for high speedsHydraulic motor II high torqueScrew cylinder fitted with universal thermoplastics nitrided screwand nitrided cylinder: non-return valve and cylinder closureassembly with SVO open nozzleScrew cylinder suitable for upto 3 injection units: L/D ratio 20:1 forall diametersFast cylinder change with central connectors for heating systemand thermocouples and with automatic cylinder identification(from 430IU)Ceramic cylinder heating bandsPID controlled barrel heater bands5 self-optimising temperature control circuits for the cylinder andnozzle heating system with adjustable tolerance monitoring ofdeviation from set point and thermocouple break resistance;operating range of up to 400°C4/5 temperature circuits for cylinder heating with monitoringofdeviation and thermocouple statusTemperature of the screw cylinder feed zone adjustableInjection speed profile programmable in * position dependentinterpolation stagesFollow up pressure profile programmable in * time dependentinterpolation stagesFollow up pressure switching activated as a function of position,time or hydraulic pressureScrew speed and back pressure control, profile programmable in *position dependent interpolation stepsScrew speed input in *Injection speed input in *Monitoring of melt cushion during the follow up pressure phaseHydraulic screw retraction after follow up pressure phase and orafter plasticising process programmable dependent on position, toprevent melt droolingDelay feature for commencement of plasticising and nozzleretractionScrew rotation lock engaged until cylinder reaches set temperatureReduction in cylinder temperatures to a preset value duringmachine idle timeNozzle guard with electrical interlock for operator safetyIntrusion and cold slug removalStainless steel hopperExtended nozzle with heater bandHydraulically operated shut off nozzle (SVH)Electrical screw drive for parellel plasticizing (from IU 840 - 10500)Sprue bush temperature controlSpecial Barrier screws for better homogenization and plasticisingrates from screw dia 30Wear resistant through hardened screw and bimetallic barrel forabrasive materialsProven screw Geometry for high plasticising capacities withexcellent melt homogeneityThermoset package and sequences dia 30 to 50CPVC/RPVC/PET package25 L/D screw (for A and B)Hard chrome plated screwMelt filter nozzle from screw dia 30Dosing delay timerCold start protection for screwNozzle contact force setting through control panel with residualnozzle contact forceFast injection with accumulator, programmable (from 150Tonwards)Melt temperature measuring (SVO)Injection closed loop with servo valve
Pump unit 1 with energy saving SYDFEE regulated pumpVariable displacement pump for energy conservationLow noise drive with quiet pumps sound insulating enclosures forhydraulicsPressures and flow rates, closed loop, controlled by fastresponding DFE regulated pump
Hydraulics
mm/scc/s
rpmmm/s
L
B
H
kN
kN
mm
mm
mm
mm
mm
kg
kg
mm
kN
L
kg
mm
mm
mm
lpm
2300-553900E-55/75*7000-75/90*
1400 2000
2000
5000
Injection Moulding Machine (Detech SERIES)
Clamping Unit
1400
5000
2100 2400
9735 for IU230010590 for IU3900E
2300 2400
9735 for IU 230010590 for IU3900E11210 for IU7000
8290
2400
3900E-55/75*7000-75/90*
10500-90/110*
* Optional pump / injection unit+Optional opening stroke
##7200 for IU 600&9007940 for IU 1400 &2350
5600
1800
5600
1800
650/1000
300
139/57
1880
1450x1350
1000x900
8600
6500
7150
810 980
5700
930
450/950380/820 380/900
760/1300***
31200/33200/35100
2480
120
10630 for IU3900E11225 for IU7000
11965 for IU10500
2475
6050
1880
550/870
5500
40/320 60/320 85/420 100/420 200/580
400 600 850 1000 2000
440 660 935 1100
575310 310 380 380
1630
180/410 180/410 200/530 200/530
1365
340/790
720
1265x1265
870x870
860x860
810x810
1200x1200
580x580
7000
630x630
420 420 700 700
4500
2250 51003500
100 120 120
34002300
230180 200
180 180 285 285 ##400/580
90/45
760
69/31 70/39
580
3200 3200 4300 4300
40 60 60
80-11120-11200-11310-11
120 120
2400
120
20900/21900/24300
90/45
760/1300**
600
330/770
1370
940x940
40
2300-553900E-55/75*
** For IU7000
2400
9735 for IU 230010590 for IU3900E11210 for IU7000
800/980+
380/900
1265x1265
5500
1700/1880+
500/870
5000
870x870
7000
4500
230
120
2400
20900/21900/24300
90/45
760/1300**
2300-553900E-55/75*7000-75/90*
900-30/37*1400-30/37/45*
2350-37/45*
600 -30/37*900-30/37*
1400-30/37/45*2350-37/45*
200-15310-15/22*
430-22*
80 -11120-11
310-15/22*430-22600-22
2160
##10000/11000
*** For IU7000/10500
Total Mould carrying capacity
Max.mould.wt.in moving platen
Hydraulic Ejector stroke
Ejection Force/Retraction Force
Oil Tank Capacity
Max.Daylight between Platens
Overall Size of Platens
Distance between Tiebars
Clamping Force
Locking Force
Mould Opening Stroke
Mould Height(Min/Max)
Net Weight (Without oil)
Dimensions of machines
Cooling water requirement
Injection Unit applicable & Pump unit (kW)
## -200/580 With 600/900 IU
2000
120
2000
20900/2190013200/14200
45/2545/2528/13
2000
28/13
230
1500450450280280
100
720
420x420420x420320x320320x320
480x480 480x480 600x600 600x600
910910
125/510
1250
200/550
720x720
510x510
1100
160
45/25
310-22430-22600-22900-22
6500
6650
1600
60
2000
310
700
1375
450
1000
150/510
1500
200/550
720x720
510x510
1100
160
45/25
310-22430-22
600-22/30*900-22/30*
6500
6650
60
2000
1600
310
700
1650
450
1000
4500
450/810
49502200
325/630
3250
3575
B C A B C A B C A B C A B C D A B C A B C
50 60 50 60 70 60 70 80 60 70 80 70 80 90 95 80 95 110 95 110 130
20 20 20 20 20 20 20 20 20 20 20 23 20 20 20 24 20 20 23 20 20
2022 1404 2565 1780 1300 2420 1877 1437 2557 1878 1438 2423 1855 1516 1316 2391 2094 1562 2434 2006 1436
442 636 530 820 1116 891 1212 1584 919 1251 1634 1636 2137 2704 3013 2388 3367 4515 3899 5227 7300
402 579 482 746 1016 811 1103 1441 836 1138 1487 1489 1944 2461 2742 2173 3064 4108 3548 4756 6643
159/223/313 228/322/450 176/246/301 253/355/433 345/483/590 373 508 663 230/281 313 /383 409/500 393/447 513/584 650/739 724/823 406/490 572/691 767/926 538/634 721/851 1007/1188
37/52/- 56/-/- 26/36/45 40/58/70 58/82/99 60 87 122 56/69 81/99 114/139 59/65 83/91 101/110 133/146 62/78 100/125 144/181 80/98 116/141 164/200
22/31/43 33/46/65 - - - 41 59 83 33/40 48/58 67/82 48/52 67/74 81/90 108/119 41/51 66/82 95/119 54/66 78/95 110/135
- - - - - - - - - - - - - - - - - - - -
270 290 290
14.8 23.1 14.8 23.1 27 23.1 27 30.6 23.1 27 30.6 31 31 43 43 43 43 59 59 59 79
110
315
55 90/110
110
45
75/90
550
45
110
45
475325 425
70
45
68 70
37/45 55/75
110
20 45
Specifications are subject to change due to continuous improvements
30/37/4522/30/37
225
45
A
45
20
2496
358
325
128/181/253
24.5/35/-
14.5/20/28.5
-
11.3
A B C A B C A B C A B C A B C A B C
mm 18 22 25 22 25 30 25 30 35 30 35 40 35 40 45 40 45 50
20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20
bar 2778 1860 1440 2591 2006 1393 2740 1900 1400 2755 2024 1550 2644 2025 1600 2448 1934 1567
cc 23 42 54 42 61 88 61 106 144 106 168 220 168 231 293 231 323 399
g 21 38 49 38 56 80 56 96 131 96 153 200 153 210 266 210 294 363
cc/s 73 109 141 78 101 146 71/71 102/102 139/139 74/74/116 100/100/158 131/131/207 121 158 200 132/186/261 167/236/330 207/291/408
g/s 4.5 7.5 14 7.5 13 19 12/12 16/16 22/22 13/13/21 18/18/28 25/25/39 21.5 31 44 25.5/30/- 36/-/- 48/-/-
g/s 4 6.5 12 5.5 10 14 9.5/9.5 13.5/13.5 18/18 10.5/10.5/16.5 14/14/22 20/20/31 18 25.5 36 20/23/28 28/32/39 38/44/52
g/s - - - - - - - - - - - - - - - 15/20/22 22/26/31 30/42/47.5
mm 90 110 110 110 125 125 125 150 150 150 175 175 175 184 184 184 203 203
mm
kN
kW 5 5.1 5.7 5.1 5.7 8.3 5.7 8.3 9.4 8.3 9.4 11.1 9.4 11.1 11.3 11.1 11.3 14.8
kW
Injection Moulding Machine (Detech SERIES)
Theoretical value, actual value depends on material grade, melt density
45 45
68 68 68 68
20 20
68
1400 23502300 105003900E 7000900430 60080 120 200 310Injection Unit Size
Plasticising flow in PS#
Max.Nozzle dipping depth(SVO)
Nozzle Contact force
Heating Capacity
Pump unit
Shot weight in Polystrene(PS)
Rate of Injection in PS#
Screw Stroke
Stage I
Stage II
Stage III
Screw Cylinder
Screw Diameter
L/D Ratio
Injection Pressure
Cylinder Head Volume
#Achieved in air injection
22/30/372211 11 11/15* 11/15/22
68
4545