24131 - Automatic PU foams pouring line
The production station has been designed to ensure maximum efficiency, precision and operational safety when working in conjunction with the operator. It is intended for use in mass production, where reliability, accuracy and ease of use are key. The machine is used in moulding processes that require automated control and a high level of safety.
Description of operation
The production process consists of the following stages:
- The operator places the moulding components into the mould.
- Upon pressing the START button, the roller shutter separating the workstation is lowered and the trolley is levelled for the casting process.
- The gantry moves into position and sends a request to an external device to fill the mould.
- Once the filling is confirmed, the gantry leaves the area, and the trolley closes the mould, locks the mechanism and activates the air cushions.
- The foam moulding process begins according to the set time and tilt angle.
- Once the process is complete, the trolley positions the mould in the open position, and the shutter rises, allowing the operator to remove the finished part.
Machine design
The station is equipped with two independent XYZ gantry systems, controlled by a Siemens SINAMICS S120 system. Inside, there are eight independent workstations, each of which has a specialised carriage for mould assembly. The functionality of each carriage includes:
- Independent heating of each mould half with PID control
- Control of mould components: pneumatic cylinders, suction cups, presence sensors
- Tilting frame controlled by a gear motor with an inverter
- Mould closing and opening mechanism controlled by a gear motor with an inverter
- Pneumatic bolts ensuring safe closing and opening of the mould
- Pneumatic cushions enabling the closing of moulds of varying heights
Advanced safety features include:
- Safe drive position monitoring
- Safe speed limitation
- Safe drive stop
- Lockable access doors
- Safety curtains at each workstation
- Magnetic safety limit switches
- Sensitive safety edges on the roller shutters enclosing the work areas
Benefits for the customer / user
The production station combines modern technology with a high level of safety and ergonomic working conditions. Thanks to advanced automation and independent workstations, the user benefits from:
- Increased productivity and reduced production cycle times
- High moulding precision and process repeatability
- Comfortable and safe operation
- Flexibility through the use of a wide range of different moulds
- Minimisation of the risk of errors and breakdowns thanks to advanced control systems
