IMC Semi Automatic Cosmetic Powder Pressing Machine

INTERNATIONAL MACHIINE CONCEPTS

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IMC Semi Automatic Cosmetic Powder Pressing Machine

Operation Manual


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CONTENTS:

Chapter 1: Safety Precautions (3)

Chapter 2: Mechanical Application (3) Chapter 3: Mechanical Specifications (4) Chapter 4: Safety Warning Symbols (4) Chapter 5: Environmental Conditions (4) Chapter 6: Environmental Noise – Estimated Value (4) Chapter 7: Mechanical Handling Method (5) Chapter 8: Mechanical Installation Method (5) Chapter 9: Emergency Steps (7) Chapter 10: Operation Precautions (8) Chapter 11: Automatic Flow Chart (9) Chapter 12: Panel Operating Instructions (10) Chapter 13: Adjustments (15) Chapter 14: Operation Method (23) Chapter 15: Troubleshooting (24) Chapter 16: Maintenance (24) Appendix 1: Electrical Control Diagrams (25) Appendix 2: Pneumatic Circuit Diagram (26)

Attachments:

Equipment List

Spare Part List

Default Settings for the PLC


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Chapter 1: Safety Precautions Before operating the machine, the operator must read and understand this operation manual and the safety precautions in detail. Only personnel who know the machine and are familiar with the mechanical risks and rules may repair the machine or carry out maintenance on it. Ensure that there is no danger to anyone around the machine before starting it. When the machine is running, no changes or adjustments may be made to the mechanical components and related devices. Repairs and services may only be carried out after the machine is shut down. Wet tools and objects are forbidden near the machine. The operator may not operate the machine if wearing wet clothing. Please ensure the operating voltage, mechanical pressure and earth connection are all set or connected correctly before connecting the power. Do not knock the electrical equipment in the control area. The safety warning symbol may not be removed under any circumstances. The safety switch may not be damaged and it’s function may not be altered. The safety door should be closed at all times. The main switch must be off when the machine is not operating. The operator must fully understand the safety equipment rules before operating the machine. When installing or repairing the machine, only personnel busy with the task at hand may be in the vicinity of the machine. Only qualified personnel may adjust the device inside the electric cabinet. Foreign objects must not be placed on the machine as they may fall in and cause serious damage or an electrical explosion. Heavy objects, tools and other sundries must be kept away from the power cord to avoid breaks in the insulation sheath which will expose live wires and result in injury. The power cord must not be in the path of any personnel. The machine must be installed on a level surface to avoid abnormal operation.

Chapter 2: Mechanical Application The IMC semi automatic cosmetic powder pressing machine has the following functions: The quantity of the mould cavity can be changed according to the different sized aluminium trays. Powder is pressed from the bottom to the top by hydraulic drive with a high and low pressure device, enhancing the stability. Two scales control the pressing pressure and with the air eliminating action, reduces the risk of defective products being produced. The numerical hydraulic control system, hydraulic pressure and speed are set at the operating panel, making it easy to operate. There is an auto batching control system and a semi-automated mould releasing system.


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Chapter 3: Mechanical Specifications

Chapter 4: Safety Warning Symbols

Caution! Electricity!

Chapter 5: Environmental Conditions The temperature of the environment should be 0~50℃. The humidity should be 20%~85%RH. The environment should be dust and pollution free.

Chapter 6: Environmental Noise – Estimated Value When running, the noise value produced is less than about 65dB(A).

No. Specification Size

1 Outline Dimensions 170x77x175cm (L×W×H)

2 Operating Power Source AC380V，3ψ，50HZ

3 Air Pressure 5~7kgs/cm2

4 Rated Voltage 3.5KW

5 Oil Cylinder Size FAФ150Xф80x80ST

6 Hydraulic Horse Power 3HP hydraulic motor

7 Rolling-cloth Motor 5IK60GU-CF（5GX30KB）

8 Production Speed 3-5moulds/min


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Chapter 7: Mechanical Handling Method In order to protect the machine from being damaged during transportation, the machine should be packed in a wooden case or packaging film according to the distance. If protected by a wooden case, when the machine arrives, two methods of handling and unloading can be done: Use the stacker to unload the machine from the wooden case. If the machine is without wheels, a stacker must be available to lift it. If the machine has wheels, it can be manoeuvred manually. When handling the machine, screw up the shockproof feet. 2-3 people should move it.

Chapter 8: Mechanical Installation Method Before operating the machine, the air pressure, power supply and hydraulic pressure must be connected properly and adjusted to standard settings. Access power supply The switch of the electric cabinet must be in the OFF position.

Then access the mechanical power AC380V, 3ψ，50/60HZ

The switch must be

OFF


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Adjust the air pressure Connect the air pressure source to the C-type quick connector on the left. Adjust the pointer of the pressure gauge to 5~7kgs/cm2 by adjusting the pressure regulating button. The pressure regulating button must be pulled up to rotate it, clockwise will increase pressure while counter clockwise will reduce pressure. After adjusting the pressure, press the pressure regulating button down. Hydraulic pressure refuelling Put the oil into the hydraulic pressure unit until it reaches the specified level on the liquid level meter. When changing the oil, pump out the oil from the hydraulic pressure unit and then refuel with new oil.

Pressure gauge

C-type quick connector (connect air pressure here)

Pressure control

Slide release valve: 1) Push down to relieve pressure. 2) Pull up to increase pressure.


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Chapter 9: Emergency Steps In case of emergency, follow these steps: In case of emergency, press down the emergency stop button on the control panel to stop the machine immediately.

Refuelling/pumping mouth

Liquid level meter

Emergency stop button


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After pressing the emergency stop button, the problem must be found and immediately resolved. After the problem is resolved, rotate the emergency stop button to the right until it springs back out. The START button on the control panel will have to be pressed to restart the machine.

Chapter 10: Operation Precautions

No. Precautions

1 Installation

Only qualified personnel can lift the machine.

Do not knock the machine while lifting.

Keep the machine horizontal (using levelling ruler.)

Install the machine in a well ventilated, spacious and dry place.

2 Wiring

Power connection must be made by qualified personnel.

Connect the earth wire, bad earthing increases risk of electric shock or

fire.

Before starting the machine, ensure that the emergency switch is easily

accessed.

Do not touch anything inside the electric cabinet while the machine is

running to avoid electric shock or injury.

Lock the wiring terminal screws which connected the power supply & the

machine to avoid fire.

3 Operation

Before running the machine, the settings must be adjusted to meet the

user’s parameters, otherwise the machine may not function normally.

Do not put your hand into the machine when it is running.

The operator must be trained to operate the machine.

4 Air pressure

The operating pressure is 5~7kgs/cm2, less than 5kgs/cm2 might cause

the machine to function abnormally.

Excess water in the pipes might cause the pneumatic system

components to not work properly. The water filter device must be

checked often.

Avoid using the machine in an environment where corrosive gas,

chemical solutions, sea water and vapours are present.


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Chapter 11: Automatic Flow Chart


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Chapter 12: Panel Operating Instructions Before operating the machine, the operator must read and understand the panel operating instructions in detail. This operation panel operates the machine using data entered by the operator. Buttons and functions

A1: Press down both buttons at the same time, (when set to auto-run) the machine will

perform according to the auto-program action. The machine will not operate if you only press one button.

A2: Power switch. Rotate this switch to ON, the machine starts up. Rotate this switch to OFF to cut off the power.

A3: Power light. A4: Emergency stop button: interrupt the mechanical performance. (NOTE: after interruption, the machine should be restarted. Rotate clockwise until it springs out to restart the machine). 12.3 The parameters are adjusted on the control panel according to the powder type, size and thickness. Not all products have the same parameters. Before putting in the parameters, the operator must read and understand the operation panel instructions in detail.

BUTTONS

A1 Start Button

A2 Power Switch

A3 Power Light

A4 Emergency Stop

A1

A2

A3

A4


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12.4 Start Up Screen:

For English

For Chinese

Press down this button, the machine will come into auto operating interface. See diagram below.


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Note: Related parameters of medium pressure and high pressure should be set according to the low pressure method from auto interface.


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12.5 This interface is mainly used for repair reference.

Press this button for manual operation.

Motor Start-up

Manual Up, machine will perform rising action.

Manual Down, machine will perform falling action.

Manual roll cloth

Switch to start-up interface.

Switch to auto operating interface. See diagram below.

Switch to I/O monitoring interface. See diagram below.

Select FAST, manual lifting will be fast.

Select SLOW, manual lifting will be slow.

Long press here 10 seconds, dialog box of below picture will pop-up.


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Note: Normally, it is not necessary to adjust the parameters. Set this parameter only in case the set pressure is not matching oil-pressure gauge’s corresponding pressure

Start up motor then set parameters on corresponding testing pressure value. For example, TEST 10, that is, test 10kgs pressure, set 30 or other number in the left column, press TEST 10 button. Check if the oil-pressure gauge’s pressure reaches 10kgs, if more or less, change the number in the left column accordingly. Others’ setting method is the same.


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Chapter 13: Adjustments Mechanical adjustment is divided into three parts. They are: mould, rolling-cloth and hydraulic pressure respectively. Mould Installation Procedure: Before installing the moulds, the operator must read and understand the mould installation instruction in detail and install the moulds according to the mould installation procedure. Match the big female mould and lower male mould and tighten the screws. Prepare big female mould and place in horizontal position. Put the small female mould on the big female mould and align the holes. Prepare upper male mould, lock the locating pin.

Lower male mould

Big female mould

Small female mould

Big female mould

Upper male mould

Locating

pin


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Match the big female mould, small female mould and upper male mould from bottom to top, adjust gaps and align holes. Match the above mentioned step 5 combination with lower male mould. Assemble the guide board on both sides of small female mould.

Upper male mould

Big female mould

Small female mould

Lower male mould

Guide board


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a. Assemble the back block.

Manually closing the moulds, the male and female mould holes must align. Tighten the screws of upper mould board and upper male mould to fix upper male mould in place. Manually open the mould to a suitable position so as to take out the small female mould to feed powder in.

1

0

Back block


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Rolling-Cloth Installation Diagram and Precautions Adjust the rubber wheel and cloth roller to be parallel. Loosen the three screws of the fixed rod. Press the cloth roller properly, tighten the fixed rod set screw 1 (back view of machine). Press the cloth roller properly, tighten the fixed rod set screw 2, 3 (front view of machine)

Drive shaft

Rubber wheel

Cloth Roller

Fixed rod set screw

1 (M6)

Fixed rod set screw 2

(M6)

Fixed rod set screw 3 (M5)


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a. When adjusting the rubber wheel and cloth roller as per above, if one side has a

gap and the other side has no gap, causes might be: Did not press the cloth roller tightly. Any one of three screws did not tighten. All three screws did not tighten.

No gap

Gap

Regulate this screw to adjust the gap between rubber wheel and cloth

roller, then tighten the nut after adjusted

to proper position.


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Back View of Machine Rolling cloth trend Hydraulic Unit Liquid Line Precaution and Diagram Please use ISO AW46 or AW68 or fit circulating oil or hydraulic oil. First change the oil once every 6 months (or 1500 hours) then only once a year (or 3000 hours). Oil tank temperature should be kept below 60℃. The specification of the motor is 220V/380V 50HZ/60HZ, set voltage is 380V.

After adjusting, adjust this fixed

screw cap to proper tightness.

This set screw can fix the horizontal position of

rolling-cloth.

Regulate this screw to adjust

and fix the horizontal position

of rolling-cloth, also can adjust its

center position.

Back View Front View


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a. The hydraulic unit must be in a well ventilated place.

b. Hydraulic Circuit Diagram


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c. Hydraulic Unit Adjustment Variable pump pressure adjustment: Take down oil-outlet pipe of variable

pump, connect oil pressure gauge, energize to pumping, ensure pumping rotated clockwise and oil tank has oil, then adjust the screw on the top of variable pump until pressure gauge set at 30-35kgs/cm2.

Proportional valve exhaust: Loosen any one of the three screws behind the proportional valve, release air until pressure pointer stops jittering when manually closing the mould.

Proportional valve zeroed: Rotate the screw on the tail of the proportional valve to the top until the pressure indicator is on ZERO. At this moment, proportional amplifier board can not be putting out voltage, otherwise it is impossible to be on zero. Adjust the pim of the proportional amplifier board counter clockwise until proportional amplifier board is not putting out any voltage.

Pressure-regulating valve adjustment: Firstly, the proportional valve must be at zero. Increase output voltage of the proportional amplifier board. Press the manual closing mould button after entered into the manual interface. Tighten the pressure-regulating valve after pressure reached 150kgs/cm2.


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Chapter 14: Operation Method Start Up Procedure: Step 1: Activate voltage and air pressure. Check the voltage, air pressure and earthing are all correct. Press powder as follows:

1

Put aluminium tray in small female mould

2

Put small female mould into powder feeder and fix position

3

Push and pull powder feeding frame hopper. Surface must be smooth

4 Set parameters on control panel

5

Push both start buttons at the same time

6

Put the small female mould into the releasing frame and fix the position

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Press out the product

8

Push the product on to the powder suction area


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Chapter 15: Troubleshooting

Chapter 16: Maintenance In order to ensure the machine runs smoothly and to extend its usage, the following maintenance must be done. Before carrying out maintenance on the machine, shut off the power supply and release air pressure to zero. The following points must be done during maintenance: Clean the machine. Check if there are any loose screws, nuts or bolts and tighten them. Check the connecting control lines of the external equipment. There must be no broken or bare wires. Each guide rod position should be wiped by cloth with oil. No oil must be leaking. The above maintenance method should be carried out at least once a day.

PROBLEM ANALYSIS SOLUTION

Press both START switch buttons and machine does not start

Selection switch of operating panel is on manual

Switch to automatic state

Induction switch on mould back side light on or not

Adjust sensing distance or change inductive switch

Cylinder does not work

Check if fuse working or not Change fuse if damaged

Check if relay working or not Change relay if damaged

Check if solenoid valve resistance working or not

Change coil if damaged

Check air supply is connected Connect if not

Product does not release from mould

Check if the small hole on mould bottom blocked

Clean the residual material on mould bottom

Air pressure too high Adjust pressure

Cooling time too short Extend cooling time


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Appendix 1: Electrical Control Diagrams


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Appendix 2: Pneumatic Circuit Diagram

No. Name Specification

1Schneider PLC TM218LDA40DR4PHN

2Schneider Touch

Screen HMIGX03501

3Schneider Extension

Module TM2DMM16DRTN

4Schneider Switching

Power Supply S-5至24V-100

5 Motor 90YT60GV22

6 Reducer 90GK30H

7 Foot Shock M16×100L

8 Hex Nut M36XP4.0 8 grade

9 Spring Washer M36 8 grade

10 Spring Washer M24

11 Adjusting Bolt M6х15L

12Flat Wire Compression

SpringSWF

∮

40-80 compression ratio 50%

13 Exhaust Fan 200×200 200V.AC

14 Nozzle M10

15 Slide Rail 300MM

16 Hose Clamp

∅

60-

∅

80

17Handle Selecting

SwitchH-4-1/4"

18900 copper bend

(internal and external

teeth )

1/4"X1/4"

19C-type Quick

Connector1/4"

20Pressure Regulating

Filter UFR-02-D

21Slenoid Valve AM520--1/4"-S

22Cylinder JC-50B20

Equipment List

No. Name Specification Photo

1 Tension springouter diameter

∅

10, wire diameter ∅

1.2 , free length 110

2 Cramp ring C-type cramp ring A-17

3 Cramp ring C-type cramp ring A-30

4 Bearing 6006ZZ

5 Bearing 6003ZZ

6

bearing6001ZZ

7 MS bearing DU1210

8 Universal

driving belt (D=6mm perimeter 500mm)

9 Batching width=210mm)

10

Speed

regulating

valve

JSC6-02

11

Labor-saving

quick

connector

JPL6-02

12Dustproof oil

sealLBH-80

13Dustproof oil

sealLBH-20

Spare Parts List


14Dustproof oil

sealLBH-50

15 Seal ring OP-09

16 Schneider PLC TM218LDA40DR4PHN

17Schneider

Touch ScreenHMIGX03501

18 Motor 90YT60GV22

19Pressure

regulating filterUFR-02-D

20 Sensor RAYCHOM ES-015

21 Air switch Schneider IC65N C32A

22 Contactor Schneider LC1 E25 10

23 Circuit board

24 Relay OMRON MY2N-J 24VDC

25 Relay OMRON MY2NJ 220/240VAC

26 Transformer FATO BK-500


27PLC power

supply

28 Solenoid valve ZHICHENG 4C210-08

29Hydraulic

pressure meter

Default Settings for the PLC

Documents

IMC Semi Automatic Cosmetic Powder Pressing Machine