臺州市黃巖新柯機械廠位於臺州市黃巖區新前街道，主營汽車焊接尾燈的生產、研發、銷售，本廠秉承“以誠信為本，以技術為核心，以服務為宗旨”的企業理念，竭力用優良質量，以效益為中心，以質量為主題，以管理為主線，以技術創新為動力，靠質量求生存，靠服務闖市場”的宗旨。不斷的求新、改善、為瞭進一步拓展市場，我們恪守“誠信、求實、開拓、創新”的企業精神，一如既往的奮進不息，為新老客戶提供優質的服務。歡迎新老客戶來電洽談！

適用范圍：

主要適用於PP、PE、尼龍、ABS、壓克力、POM等熱塑性材料及焊口麵積尺寸大而復雜的塑料工件焊接。例如：汽車尾燈、方向燈、汽車水箱、油箱、碳罐、製動液罐、保險桿、機表盤、尾氣凈器、蓄電池、摩托車瀝清器、洗衣機塑料平衡圈

機器特點：
1.操作簡單易學，應用范圍廣；
2.針對工件的內部、不規則形狀的工件，焊接出密封強度高且一致工件，無耗材（如膠水、溶劑、粘合劑等）；
3.采用人機界麵配合PLC電腦控製系統，機器動作無誤，操作方便安全；
4.速度快省人工，生產效率高；
5.數字式的PID溫度控製，熔接溫度更加穩定

一：機器用途及主要技術參數Applications & Main Technical Parameters

用途：Applications：

主要運用於熱可熔性塑料的熔化與粘結（熱封），：汽車車燈的麵罩與燈體的焊接。

Mainly apply to the melt and bond (heat seal) of the thermoplastic material, eg:the welding of the auto lamp housing and body.

主要技術參數：Main Technical parameters：

1. 電源：AC380V/50HZ  Power：AC380V/50HZ
2. 工作氣壓：0.6—0.7MPa  Working air pressure：0.6—0.7MPa
   1. 機器外形尺寸：1720*1260*2100（除氣缸外）

    Machine outside measurements:1720*1260*2100(not include theair cylinder)

1. 加熱控製：采用溫控機控製，熱電偶測溫，閉環控製，控製精度高。（分6組加溫，，上模1和下模為主要加溫。其他上模2-3和下模2-3為輔助加溫，主要用途模具異形溫度不準進行補充使用）

      Heating Control：Operated by the temperature controller, measure the temperature

       by the thermocouple, closed-loop control, with high control accuracy.(Divide into 6

         groups to heating: Upper Mold 1 and Lower Mold are primary heating,other Upper

         Mold 2-3 and Lower Mold 2-3 are secondary heating.Consider as the supplemental

         Application when the mold abnormal and the temperature is inaccurate.

1. 電氣系統控製：PLC+觸摸屏

  Electric control system：PLC+ Touch Screen

1. 熱模緩沖：采用雙氣缸，液壓減速使熱模退位更加平穩（緩沖阻力可根據模具重量調節）（專利審批中）

     Hot-mold buffer: adopt the double cylinders,hydraulicdeceleration make the

         hot-mold exit moresteady（buffer resistance can be adjusted according to the

         mold weight)(under the patent examination)

1. 上吸氣：采用吸氣泵，產生負壓，並自動檢測壓力大小啟動電動機（要選擇真空泵開啟）使用過程需用腳踏開關打開。每次如此（此方法可以保持真空吸力）方可控製麵罩變形提高產品合格率。

      Upperair inspired:generate the subatmospheric pressure by the getter

         pump,automatically detecting the pressure and opening theelectric

         motor(should choose the Vacuum Air Pump ON),keep the foot (pedal) switch

         ON in using. Should repeat the operations every time(In order to keep the Pull

         of Vacuum) to avoid the lamp cover deformation and increase the pass rate.

1. 時間設定.上下模具熱熔時間均可延時設定（跟具產品設定）（0——99秒）熱熔-固化設定時間（0——99秒）

       Time Fixed: could set the hot melting time(0-99 s)-Curing (0-99 s)for upper    

             mold and lower mold(According to the different products)

1. 其他功能可根據產品要求選擇使用或不使用

  Other functions are optional.

1. 行程開關使用方法。The Use Method of Travel Switch

行程開關使用電磁式。熱模使用3個。（1）.熱模氣缸尾部{註明，熱模原點}在自動運行開關前，此點一定要亮（才可自動運行）如果不亮或自動運行不瞭，熱模已經退到位的情況下。請把{熱模原點}移到會亮的狀態。（2）.熱模中部{註明，退模位置}此行程開關起提前合模的做用。一般方置氣缸中部或中部向前50——150MM（具體位置與上下模退模位置來定）（3）.熱模前部{註明，熱模信號}此行程開關起熱模到位，起動上下模具熱熔使用。如果熱模已經到位上下模不動，請把{熱模信號}移到會亮的狀態。（4）.上下模行程開關使用方法。上模使用4個點。從上往下第【1】{註明，上模原點}此行程開關，在自動運行開關前，此點一定要亮（才可自動運行）此點不熱模不會退位。下模使用4個點。從下往上第【1】{註明。下模原點}上下原點使用功能一致。(5).從上往下第【2】{註明，熱熔退位}此行程開關設定，在自動運行時上模退位到熱模能自如退位的位置，不可過低，否則熱模會掛到上模模具。此點還起到上模下降減速功能。和下模【2】功能一致。（6）從上往下第【3】{註明，上模熱熔}此行程開關設定起熱熔機計時。上模具在下降到產品接觸到熱模高度以上（經過就可以。單一定要高於模具已接觸高度否則熱熔時間不計時）（7）

The travel switch adoptselectromagnetic system.The hot mold uses 3travel switch.(1)Tail of hot mold air cylinder{Marked as Hot Mold Initial Point}。The point must be ON before the automatic operation.If the point not come ON or fail to automatic operation,but the hot mold is ready to exit,please move the {Hot Mold Initial Point}to ON position.(2)The Middle of Hot Mold{Marked as Mold Exit Position},the travel switch acted as the mold clamping switch.Generally placed in the middle of the cylinder or forward 50-150 MM from the middle position(the specific position should be up to the exit position of the Upper & Lower Mold).(3)The Front of the Hot Mold{Marked as Hot Mold Signal}.This travel switch move the hot mold to its position,and start the hot melting of the Upper & Lower Mold.If the hot mold on its position,but the Upper & Lower Mold don't move,please move the { Hot Mold Signal} to ON position.(4) Use Method of the Upper & Lower Mold Travel Switch.The upper mold use 4 points.The No.【1】goes from the top to the bottom{Marked as Upper Mold Initial Point},The point must be ON before the automatic operation.The lower mold use 4 points.The No.【1】goes from the bottom to the top{Marked as Lower Mold Initial Point},same function with Upper Mold Initial Point.(5)The No.【2】.goes from the top to the bottom{Marked as Hot Melting Exit}.The travel switch could be set.Whenautomatic operation,the Upper Mold could travel to the position wher the hot mold could freely exit,couldn't be too low,or else the hot mold will hang on the upper mold.This point also could decelerate the Upper Mold fall down.Same function with Lower Mold【2】.(6) The No.【3】goes from the top to the bottom{Marked as Upper Mold Hot Melting}.This travel switch could control the hot melting time.The upper mold fall to the position wher the product could touch the hot mold height(Pass is OK,but the position shouldn't be higher than the mold,or else the hot melting time can't be counted.

二：機器機構Machine Constructi



on

主要由以下部分主成：機座（床身，上下模座，水平熱模板，導軌等）附圖1，流量控製（電磁閥，調壓閥，壓力控製器等），加熱控製（溫控機，加熱管等），電氣控製（PLC,觸摸屏等）等

The machine consisted of: machine base(lathe body, upper-lower die, horizontal hot-mold plate, guide rail etc.),see figure 1; streamflow control(Solenoid Valve, Pressure Regulator Valve, Pressure Controller etc.), Heating control(Temperature Controller, Heating Pipe etc.), Electric control(PLC, Touch Screen etc.) etc.

其中，床身采用鑄鐵工藝加工，具有結構穩定，變形量小，定位準確等優點；水平熱板模采用采用雙氣缸，液壓緩沖，減少床身振動；壓力控製器：負壓產生時，達到設定值自動停止吸氣；PLC+觸摸屏：結構簡單，維護方便等優點。

     The lathe body is made from casting iron technology, with advantages such as stable structure, small deflection, and accurate positioning; horizontal hot-mold plate adopt the double-cylinder, hydraulic buffer, to reduce the vibration of the lathe body; Pressure controller: automatic stop at the setting value if there has the subatmospheric pressure; PLC+Touch Screen: simple structure, easy maintenance.

三：機器安裝與接線MachineInstallation & Connection

設備安裝前，先檢查運輸途中外表麵油漆是否刮傷，設備是否有損傷等，安裝過程中，調整設備水平，並加防振墊鐵，四角固定。

Before the installation, please check whether the surface paint isscratched or not, does the equipment is damaged or not during the transportation.When installing, adjust the equipment, put on the anti-vibrationparallel，and fix the four corners.

電源穩定，接地正常及氣源壓力穩定。

   Power supplystable，earthing normal, andSource Pressurestable.

四：機器操作與調整Machine Operation & Adjustment

打開系統電源開關和上下熱膜加熱，設定溫控機的溫度為產品工藝要求值；根據模具的高度調節原點位置（原點指示燈亮），上下模緩沖位置，即可進行自動運行。位置的到位信號可以通過手動運行控製。

Open the system power supply and heating Upper & Lower hot mold, set the temperature controller on the basis of the productprocess requirements; adjust the origin position (origin position LED ON),Upper & Lower hot moldposition according to the mold height, so operating automatically. Signal coverage can be controlled by manual operation.

具體操作：Special Operations:

1. 點擊觸摸屏選擇手動運行界麵：附圖2，點擊相關的操作來檢查信號到位情況；

        Click the touch screen and choose the Manual Operation:see Figure2,and click

           the related operation to check the signal coverage.

1. 確認後，選擇自動運行界麵：附圖3，調節相關的工藝：附圖4，等到熱膜溫度到達，就可以進行自動運行。

       Click the OK, choose automaticallyOperation: see Figure 3,adjust the related

       technologies:See Figure 4,when the hot-film temperature OK, it can

       automatically operate.

1. 設備出現故障，按急停按鈕，並檢查故障出現原因，再繼續運行。

         If there has equipment fault, click theemergency stop button, and find the source

           of trouble, then continue.

註意：不瞭解設備結構性能和操作，請勿開機。

     Warning: Do not Power ON if you don't understand the equipment

     structure and operation!

五：機器維護與保養MachineMaintenance & Service

1. 定期給機器個運動部件導軌加潤滑油脂，建議每天檢查一次，不足時加油脂。Regularly Add thelubricant grease on the the guide rail of machinemoving components, suggest checking everyday
2. 定期清理氣動三大件，油水分離器中的油水，油霧器中補充適量機油，油麵不超過最高油位，不低於最低油位。

Regularly clean thepneumatic components, clean the grease in the water-oil separator,

        supplement some engine oil to the oil fogger. The oil lever should not be above the

         highest oil level and also should not be below the lowest oil level.

1. 定期檢查個氣動管路，接頭是否出現破損，泄露或者杜塞情況。Regularly check thepneumatic line, make sure there has no breakage，leakage or blockage.
2. 定期檢查電磁閥，磁性開關是否正常。

   Regularly check the electromagnetic valve, whether the magnet switch normal or not.

1. 熱板焊表麵每天必須清理乾凈，不允許有雜質和塑料焊渣，碳化物等相關物質。

     Must clean the welding plate surface every day, don’t keep impurity and plastic welding

     slag,carbide from the surface of the welding plate.

註意：Warning:

1.發現設備有嚴重漏氣或者不正常運行，請先停機檢查，故障處理後再開機。

    If the equipment seriously leak the steam or abnormally working, pleasestop the machine

       immediately to check and remove the faults, then continue.

2.根據各個公司，內部不同的設備維護，保養管理規定，對設備機械，氣動，電氣控製系統，定期進行安全維護和保養工作，建議每半個月進行一次。

    Regularly maintain the mechanical-,pneumatic- and electrical control system, suggest do

       the maintenance at every two weeks.

3.真空泵不可無油，建議每周不充一次。

    The vacuum air pump can't be out of the fuel,suggest fuel up every week.

六：機器的故障排除Machine Troubleshooting

  機器在運行過程中，有可能出現功能性故障，一般情況下，先切斷電源總開關，檢查機箱內空氣開關是否跳閘。

In case of functional fault during the running, generally, cut off the power, and check whether the air switch tripping or not.

  如熱熔過程出現故障，可根據屏幕顯示及配電櫃內PLC信號指示燈輸入和輸出信號是否正常，也可以通過屏幕I/O端口查詢：附圖5。

In case of fault during the hot-melting, please check the screen display and the PLC indicator input-output signal in electric closet is normal or not, also can check the screen I/O port chamfer: see Figure 5.

七：電氣圖Electrical Diagram

  參見附錄6.See theappendix 6.

註意：動作過程出現中斷運行，一般都是信號沒有到位引起。

Warning:there may ariseinterrupt run during the operating , which generally result from the lacking of the signal coverage.

航空插頭接線圖（16芯）

Aeronautic Plug Wiring Diagram (16 Cores)

正：Positive

負：Negative

藍：Blue

紅：Red

適用范圍：

主要適用於PP、PE、尼龍、ABS、壓克力、POM等熱塑性材料及焊口麵積尺寸大而復雜的塑料工件焊接。例如：汽車尾燈、方向燈、汽車水箱、油箱、碳罐、製動液罐、保險桿、機表盤、尾氣凈器、蓄電池、摩托車瀝清器、洗衣機塑料平衡圈

機器特點：
1.操作簡單易學，應用范圍廣；
2.針對工件的內部、不規則形狀的工件，焊接出密封強度高且一致工件，無耗材（如膠水、溶劑、粘合劑等）；
3.采用人機界麵配合PLC電腦控製系統，機器動作無誤，操作方便安全；
4.速度快省人工，生產效率高；
5.數字式的PID溫度控製，熔接溫度更加穩定

新手教學

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