Pronext, a.s.

J. A. Bati 5263, 76001 Zlín, CZ

Czech (CZ)Anglicky (EN)

Doubling machine

kasirovaciThe machine is used for backing, which means the pasting (glueing) of textile, artificial leather or leather materials to the skeleton of components, e.g. internal panels of car doors.


Machine Dimensions

Width 1650 mm
Length 2500 mm
Height 3500 mm


Height of Mould Table from the Floor

950 mm


Stroke of Mould

480 mm


Maximum Mould Dimensions

Width 560 mm
Length 1000 mm
Height 300 mm

Drive: pneumatic, pressure 0,5 MPa, air accumulator of volume 50 l
Control: electronic (programmable controller and touch screen)
Pressing force: 20106 N at a pressure of 0,5 MPa
Mould changing: according to execution P1, possibility of utilization of moulds from execution P1 to execution P2

Warming –up

infra.jpgThe upper section is composed of seven long and four short infra-red heaters. All the infra-red heaters are adjustable from the aspect of height and angle. Height adjustment 60 mm, angular adjustment without limitation. Altogether six sections of infra-red heaters can be individually regulated and switched off. (See figure: the sections of infra-red heaters are designated by the same colour)
Short infra-red heater: length 500 mm, output 2260 W
Long infra-red heater: length 700 mm, output 3180 W
The bottom warming-up section is identical to the upper section.
Total installed output: 62,6 kW

Lighting: by two halogen lights from the side of the machine.

Suction holding of components in the upper part of the mould: with the help of four suction pads and four injectors with filters. The suction parts are not a component of the machine. Control by a foot pedal.

Exhaustion of vapours: An exhaust nozzle is prepared for the bottom half of the mould. The exhauster is not a part of the machine.


Cooling:  Interconnection of the machine with the two halves of the mould and cooling unit is executed. The cooling unit is not a part of the machine.


Technical Description of the Machine

The machine is pneumatically powered and of box construction. Control is through a programmable controller and monochromatic touch screen. The machine is made up of a table for the bottom part of the mould which is equipped with slide-out wheels for faster changing of moulds. Further the machine is equipped with a press head to which the upper part of the mould is attached. The pneumatic driving cylinders have a maximum stroke of 600 mm. The sliding warming-up chamber has a total of 22 built-in short-wave infra-red heaters with a golden reflector. One half warms up the upper part of the mould and the other its bottom part. The total warmed-up surface area is 1240x650 mm. The shift of the chamber is 700 mm and enables warming up of the mould and after movement into the initial position, the pressing in of the upper and bottom part of the mould. The machine is also outfitted with equipment for cooling of the upper and bottom parts of the mould. The cooling equipment maintains the set temperature of the mould. The set temperature range is from +10°C to 40°C. Suction pads are installed in the upper part of the mould. These serve to hold the skeleton of the product during attaching. Negative pressure (suction) can be utilized in the bottom part of the mould to hold the pasted material against the inner surface of the mould.


 

Procedure during mould exchange

Prior to start of changing it is necessary to disconnect the input hoses of cold water. For this purpose there are quick-release couplings on each mould. Each mould has its own material handling cart. The cart is wheeled from the side to the table of the machine. Both moulds, on the cart and on the machine, are released by rotating a quick-action vice. Then we slide the mould upwards onto the machine by turning an eccentric shaft. Simultaneously, also the slide wheels are slid under the mould. The mould is then shifted onto the empty cart. The new mould from the cart is shifted onto the table of the machine in such a way as to enable the openings in the mould to correspond to the location of the quick-action vices. Then the mould is lowered onto the table of the machine by turning the eccentric shafts and by swiveling the quick-action vices the mould is secured in the correct position.

Procedure for attaching the upper half of the mould

After correct alignment of the mould on the table of the machine the press head is lowered onto the mould and is attached by four bolts to the press head. Then the press head is moved upwards to the top of stroke, and the machine is ready for operation.


Work on the machine

Switch on the machine by the main switch on the door of the main switchboard. Air input into the machine is activated by switching on valve VV, which is located on the main input behind the air filter of the machine. Here is a pressure gauge and using the air pressure reducing valve set the pressure to 0,4 MPa. Using the foot pedal activate the function of the suction pads in the upper part of the mould. Insert the skeleton into the upper part of the mould and thanks to the action of the suction pads it is secured in this part of the mould. Then insert the backing component into the bottom part of the mould and press the press-button start, located on the control table on the fixed shoulder in the left part of the machine.

Further functions run fully automatically

1) The heating chamber moves between the open mould and the shortwave infra-red heaters. Thus both parts of the mould are warmed up. After elapse of the set period, the infra-red heaters switch off, and the heating chamber moves into the machine.

2) After the heating chamber moves into the machine, the press head, with the upper part of the mould and the skeleton of the product, commences to slide downwards. After contact with the bottom part of the mould, the running of the set time of the molding process commences, and simultaneously the vacuum in the vacuum pads in the upper part of the mould is deactivated.

3) After elapse of the molding time, the upper part of the mould lifts to its basic position and the finished product is extracted from the machine.

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Pronext, a.s. -  J. A. Bati 5263 (Area Svit - building 33), Zlin 760 01, Czech Republic  -  Phone: +420 577 523 581


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