Opportunities for Improved Production

In today’s highly competitive market, where short production runs and frequent mold changes are the norm, manufacturers must remain vigilant for strategies that can enhance productivity. Implementing a system to minimize the time required for lengthy mold changes can significantly improve efficiencies on the shop floor and positively impact the bottom line.

When evaluating the rationale and execution of quick mold change initiatives, several factors come into play. These include labor costs, machine expenses, machine capacity and downtime, as well as considerations regarding safety and ergonomics.

A comprehensive assessment of market demands, plant conditions, and technical challenges is essential to define a practical solution. Quick mold change facilitated by magnetic clamping technology emerges as a promising approach in addressing these multifaceted considerations.

In Considering Magnetic Clamping Technology

Demands in the Market

• Increasing competition
• Increasing need to control or reduce costs
• Decreasing lot sizes
• Shorter delivery times, JIT
• Decreasing inventories
• Limited capital commitment
• Flexible production needs

Shop Floor Challenges

• Frequent mold changes
• Time-consuming mold changes
• Cooling and heating of molds within machines
• Varied mold sizes
• Manual mechanical clamping methods
• Damaged fasteners and threaded holes

Challenges in Implementing Faster Mold Changes

• Minimizing downtime between parts
• Installing new molds at operating temperature

Requirements for New Clamping System

• Seamless retrofitting capability
• Heat resistance up to 240 0°C (460° F)
• Emphasis on safety

Processor Solution

• M-TECS 210: Robust, quick, and reliable mold clamping
• Rapid clamping and unclamping of hot molds in seconds
• Compatibility with non-standardized molds
• Uniform clamping across the entire mold surface
• M-TECS 210 have easy installation and integration into press machinery
• M-TECS 210 have proven performance at temperatures up to 240 0°C (460° F)

M-TECS 210: Revolutionizing Mold Change Efficiency

The M-TECS 210 magnetic clamping system enters a new era of cost reduction and productivity enhancement for the rubber industry. By employing magnetic clamping technology, mold change times are dramatically slashed, often by hours, as the need for press downtime due to mold heating or cooling becomes unnecessary. This innovative system facilitates rapid mold changes, even with hot molds, completing the process in minutes and clamping molds securely in mere seconds, ensuring both operational safety and ease for operators.

Featuring magnetic plates with fully metallic surfaces, the absence of T-slots between heaters and molds, coupled with uniform full-surface clamping force, achieves tighter temperature tolerances within the mold, thereby positively impacting part quality.

Non-standardized molds can be swiftly interchanged without modifications, resulting in reduced mold flexure and lower maintenance costs. With no moving components, the magnetic plates are virtually maintenance-free and can be seamlessly retrofitted into existing rubber injection machines or integrated into new presses, all while maintaining necessary safety standards.

Enhanced Productivity

• Reduced setup times
• No heating or cooling periods in the press
• Instant mold clamping with dual push-button controls
• Increase in annual machine capacity

Safety and Comfort

• Complete safety in the case of a power failure
• Multi-level safety system
• Reduced operator time in hot areas
• Hand tools and clamps not required, minimizing burn risks

Improved Quality

• Fully metallic surface for optimal heat transfer
• Full clamp force across entire molds, optimum contact
• Homogeneous mold temperature with no insulating T-slots
• Decreased mold wear
• Fewer rejects

Magnetic Force

The magnetic force emanates as a flat, highly concentrated magnetic field, penetrating the mold base plate by a few centimeters (less than an inch). For instance, a mold measuring 400 x 400 mm (16” x 16”) experiences a maximum clamping force of 80 kN (8 tons), while a larger mold measuring 700 x 500 mm (20” x 28”) is subjected to approximately 170 kN (17 tons) of magnetic force. This force varies based on the surface type and increases proportionately with the mold's area, ensuring uniformity across its entire surface. This uniform distribution positively influences temperature tolerance, die deformation, and maintenance costs.

Applications

The M-TECS 210 is versatile, suitable for deployment on compression and injection presses of all sizes, whether for new installations or retrofitting into existing setups. It is compatible with both vertical and horizontal machines, offering magnetic plates with or without heating platens, catering to vacuum applications as well. These plates are meticulously designed to align with the physical size, shape, and magnetic forces required for the specific application, process, press, and molds involved.

Safety and Control

Featuring an electro-permanent magnetic clamping system, safety remains paramount even in the event of a power failure. The clamping force is solely generated by permanent magnets, with current consumption limited to the brief period required for magnetization or demagnetization during mold changes. During production, power usage is minimal, devoted mainly to system monitoring. An integral safety system oversees magnetic force, mold position, and platen temperature to ensure operational safety.

Operation

Equipped with an operator's control pendant for both upper and lower platens, the system necessitates a multi-step process for magnetization or demagnetization. Operators must transition the press into setup mode, activate a key-operated switch, and simultaneously press two push buttons on the pendant for each mold half. Depending on machine size, safety features like mats and photoelectric guards may be integrated seamlessly.

Installation

Installation is straightforward and typically completed within a day. The magnetic plates are designed for easy bolt-on attachment, with wiring connections featuring plug-in type connectors for simplicity. Retrofitting involves the use of a key-operated switch with a straightforward machine interface, ensuring press interlock with the M-TECS system for secure mold changes.

Amortization

For cases involving frequent mold changes, the investment pays off within a few months. Even with one or two die changes per week, the system proves cost-effective, paying for itself within a year or two.

When evaluating system justification, while time savings and productivity gains are pivotal, cost reductions in mold maintenance and enhancements in part quality should not be overlooked.