High Precision Honeycomb Magnetic Quick Mold Change System For Injection Molding Machine
Quick Mold Change System for Injection Molding
Changing molds in a traditional system can be time-consuming, laborious and even dangerous. When you install a QHMAG Quick Mold Change (QMC) System, hydraulic or pneumatic quick mold change clamps automatically and safely fasten and unfasten the mold from the machine. The mold is moved quickly and easily, and clamped into the right position every time. Once the material for the subsequent job is put into the machine and the mold quickly clamped, your next job is ready — in the shortest possible time.
Why Quick Mold Change?
Today’s market needs are diversifying, and the world economy is fluctuating. The goal of efficient management is to achieve a just-in-time (JIT) as well as single-minute exchange of die (SMED) manufacturing process. Production lines are often required to make a relatively small quantity of parts in a short time so the order can be delivered quickly. Doing this easily and safely — while being able to compete in the global market — requires a quick mold change system.
Using QHMAG quick mold change system, injection molding operations become safer and more efficient.
Heavy tools are swiftly moved into position and are located securely and repeatably with quick change mold clamps. Faster changeover means less downtime, more capacity and increased operational flexibility. Productivity rises, and that means a healthier bottom line.
Honeycomb Magnetic Plate vs Standard Magnetic Plate
| Comparism | Honeycomb Magnetic Plate | Standard Magnetic Plate |
| Rigidity & Stability | Honeycomb type with double side magnetic suction structure, the magnet of back is stronger, so the mold, magnetic plates, and the backplane of injection molding machine are combined together, which improve the rigidity of the plate, and avoid mutual vibration and offset. | Only fix the fastening screws around the plate, can not be fix screws in the middle of plate, so it can not fully guarantee the template avoid deformation when open mold. |
| Capacity & Versatility | Thickness 37mm, increased the opening stroke, the maximum reduction of the ejector rod and the amount of injection muzzle expansion, better control of plastic temperature | Thickness 45mm, the capacity is small, so the mold range is corresponding less than honeycomb magnetic plate. |
| Service life | Created in a monolithic construction: CNC machined and is completely made in a metal, with no resins, gaskets, screws, brass or other materials. It is extremely reliable: There are no components subject to wear, deformation or thermal expansion. | Surface is sealed by resin potting, with aging risk. |
| Quality& Efficiency | Double-sided with magnetic force, the back suction function in the stripping process to maintain the mold stability, to avoid mutual vibration and offset. | Single-sided magnetism, the magnetic force in same unit area reduced 10%-15% |
| Clamping force | The honeycomb structure is optimized the inside of magnetic plate, which ensure the rigidity and strength of the magnetic plate itself, as well as the magnetic force can be concentrated in a reasonable layout, so, no matter what size about the mold, the template is with more powerful clamping force | The ordinary structure clamping force is dispersed and not uniform |
| Personnel operation | With LCD remote controller, in use of intelligent password authorization, eliminating the need for key management inconvenience, real-time quantitative feedback status of mold and the all sensors, it is more intuitive | Mechanical control box, button control, can not quantify the real-time reaction of mold status |
Quick Mold Change System Components
| Standard Configuration |
| Magnetic Plate | 1 Set | Moveabla & Fixed side, Upper & Lower side |
| Main Control Cabinet | 1 Set | 4, 8, 12 Channels. |
| Remote Controller | 1 Set | Mechanical type and intelligent LCD touch type |
| Connecion Cables | 1 Set | Control cable, power cable, Signal cable, etc. |
| Accessories | 1 Set | Mounting screws, mounting rings, positioning rings |
| Optional Configuration | Optional Functions |
| Fall Prevention Chain | Temperature Detection | Misalignment Detection |
| Die Lifter | Proximity Detection | Force Strength Detection |
| Die Arm | Magnetic Saturation | Magnetic Flux Detection |
Magnetic Plate Technical Parameter
| Item | Standard Magnetic Plate | Celluar Magnetic Plate | Full-Steel Magnetic Plate |
| Pole Size | 50*50mm | 70*70mm | 80*80mm | 70mm Hexagon | 50*50mm | 70mm Hexagon |
| Magnetic Strength Unit Area | 16kgf/cm² | 16kgf/cm² | 16kgf/cm² | 15kgf/cm² | 15kgf/cm² | 15kgf/cm² |
| Magnetic Strength Per Poles | 350kgf | 735kgf | 980kgf | 640kgf | 735kgf | 640kfg |
| Magnetic Plate Thickness | 35, 45mm | 50mm | 52mm | 37mm | 37, 47mm | 48mm |
| Magnetic Flux Penetration Depth | 15mm | 18mm | 20mm | 18mm | 18mm | 18mm |
| Ejector Hole | Standard | Standard | Standard | Standard | Standard | Standard |
| Control System | Main Contorl Cabinet | C4 | C4/ C8 | C8 | C4/ C8 | C4/ C8 | C4/ C8 |
| Remote Controller | QRC-A
QRC-AC | QRC-A
QRC-AC | QRC-A
QRC-AC | QRC-A
QRC-AC | QRC-A
QRC-AC | QRC-A
QRC-AC |
| Max. Working Temperature | 120℃,150℃ |
| Standard Voltage | AC 220V~480V, 50/60HZ |
| Proximity Sensor | ≤5000KN | 1pc | 1pc | - | 1pc | 1pc | 1pc |
| >5000KN | - | 2pc | 2pc | 2pc | 2pc | 2pc |
| Sensing Distance | 0.2mm |
| Temperature Sensor | Standard, Detection temperature from 60 to 200 degrees |
| Dislocation Sensor | Standard, Detection accuracy 0.1mm |
| Magnetic Saturation Sensor | Standard, Detect whether the electric current is saturated |
| Magnetic Flux Sensor | Optional, Detect changes in magnetic flux |
| Force Measurement | Optional, Detect the strength of the magnetic force |
| Surface Seal Material for Both Side of Magnetic Plate | Surface Material of Front Side | Resin | Resin | Resin | Metal | Metal | Metal |
| Surface Material of Back Side | Metal | Metal | Metal | Metal | Metal | Metal |
Advantages of Magnetic Clamping System
1. Easy Installation
It does not require any changes to the molds,no need to change the appearance and structures, no need punch, just fix the magnetic plate by bolts in the rear panel threaded hole or T-slot of the injection molding machine.
2. High Safety
The Magnetic quick mold change is controlled by Electro-permanent magnet system which is an electrical pulse activates the system in a second (Magnetization): the mold is held by the natural force of the permanent magnets. The clamping force remains constant even in the absence of a power supply, it is still keep strong and continuously magnetic force when power off and does not disappear or loss by time and temperature factors.
3. High Efficiency
Use Magnetic quick mold clamping system can greatly improve the mold change efficiency, drastically reduces mold changeover times (up to 90%) compared to a conventional procedure. QMCS guarantees a uniform mold clamping, that is held using the whole contact surface. Clamping the mold with uniformity allows obtaining good quality parts even with the first molds. The two mold halves are perfectly aligned: friction is minimized, preserving wear of molds and the machine. Generally the mold change and mold clamping only need 3 minutes, large mold change only needs 10 minutes.
4. Save Space
The thickness of Magnetic plate is about 37-50mm, space is small. The magnetic quick mold clamping system does not use platens and other pneumatic and hydraulic components,save more space and make all the peripherals of the mold in the injection molding machine are easy for maintenance and operation.
5. Easy Operation
Magnetic quick mold clamping system clamps molds of any shape and size with strength. A single operator easily and safely performs the operation, without working inside the machine.
6) Economical and Practical
Use Magnetic quick change mold system means eliminating the cost of maintenance and management of brackets, consumables, fasteners.Electricity is only used to fix and release clamping, once the mold is safely held to the correct position, will no longer need to use the electricity. Magnetic chuck application temperature can maximum up to 150°C, machine weight up from 60 tons to 5000 tons.
| Customer Information |
| Company Name | | Company Address | |
| Contact Person | | E-mail | |
| Telephone | | Fax | |
| Injection Molding Machine Information |
| IMM Brand&Model | |
| Opening Force | kN | |
| Clamping Force | kN |
| Nozzle Force | kN |
| Ejector Force | kN |
| Mould Capacity | mm |
| Max temperature of Mould | ℃ |
| Enclose Back- plate Drawing | |
| Mold Information |
| Mold Parameter | Length(mm) | Width (mm) | Height (mm) |
| Maximum size of the mold | mm | mm | mm |
| Minimum size of the mold | mm | mm | mm |
| |
| The max weight of mold | kg | The min weight of mold | kg |
| Diameter of Mold Centering ring | mm | Mold Back-plate Material | |
| Mold with Insulation board | YES
No | Mold with automatic thread demoulding structure | YES NO |
