Transcription
Technical dataEvolution 1 05 DL21/12Technical dataContents2.1Identification data . . . . . . 32.2Machine type designation . . . . . . 32.3Directed use . . . . . . . . 42.4Ambience . . . . . . . . . . 42.5Electrical connections . . . . . . . . 42.6Dimension I Weight . . . . . . . . . . . . . . 52.7Driving unit I Hydraulics . . . . . . . . . . . 62.8Closing unit . . . . 72 .9Shot unit . . . . . . . . . . 82 .10Production data . . . . . . . . 92.11p/0 2 -Diagram . . . . . . . . 92 .12Noise level of the DCM . . . . . . . . 102 .13Peripheral units . . . . . . . 112.1 4Enclosures . . . . . . . . . . . 1112-9906-001-AA1OSL Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
2/ 12Technical dataEvolution 105 DLSoftwarePage Maker 6.5 Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil12-9906-001-AA 105L
Technical dataEvolution 105 DL2.13/12Identification dataCustomer1111 Honda WayMaschine-Type:Evolution 105 DLYear of construction:2001Order Number:574 907Maschine-Number:10 335 7902.2Machine type designationMaschine-serial EVOLUTION 1 05 DL/Type of closing unitType of injection unit12-9906-001-AA105L Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
4/ 122.3Technical dataEvolution 105 DLDirected useBuhler horizontal die-casting machines are designed exclusively for the pressuredie-casting of aluminium, magnesium, zinc and copper alloys. Any use beyond thisscope is regarded as non-directed.The manufacturer can not be made liable for any damages that are a result of nondirected use. The user is the sole bearer of the risk for such damageThe observance of the conditions for installation, start-up, operation and maintenanceas instructed by the manufacturer are inherent with the directed use.2.4AmbienceIn order to determine a suitable location tor the DCM or DCI a number of importantaspects will have to be taken into account.See chapter ,Preparing the site of installation".2.5Electrical B-13702-00t.:480 v ( 10%)60 Hz90 kW Copyright 1999 BOhler Druckguss AG, C H-9240 Uzwilv480( 10%)60 Hz95 kW12-9906-00 1-AA 1OSL
Evolution 105 DL2.6Technical data5/12Dimension I WeightMachine ready for production :. . . . . . . . . 55'000 kgWeight of the control cabinet: . . . . . . . . . . . . . . . 464 kg500180060000-.::t480320. .-0 co eo:.;!t.;!00000coC\J00co.am. :.!-.00 00T"""0 I12-9906-001-AA 105LGEB-12310-00 Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
6/ 122.7Technical dataEvolution 105 DLDriving unit I HydraulicsMAIN MOTOR M1HYDRAULIC TANKInstalled load:. 90 kW5o7. 2t «Jc:" ""T3Filling quantity: . 1920 dmNumber of revolutions: . 1780 U/minSUCTION FILTERTransmittance: . 200 11VARIABLEDISPLACEMENT PUMPDisplacement: . 175 I/ minFIXED DISPLACEMENTPUMPDisplacement: . 219 I/minPARTIAL FLOW PUMPDisplacement:··· 113 I/ minLOW PRESSURE FILTER(Transmittance: . 10 11PUMP/CLOSING HYDRAULICSHEAT EXCHANGERMax. operating pressure: . 210 barOptimum operating temperature:. .43 ocOperating pressure: . 3- 10 barWater temperature supply line: . 5- 30 ocWater consumption*:. 3.5 m3/h( Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil12-9906-001-AA 105L
Technical dataEvolution 105 DL2.87/12Closing unitDIECENTRAL LUBRICATIONFilling quantity: . . 15 dm3Die height: . . 610 -1170Die opening stroke: . 740Max. permissible surface pressure: . 100Min. permissible die dimensions: . 800 x 800mmmm )mm\EJECTORTIE BARSTie bar spacing: . 1118 x 1118Tie bar diameter:. 200Tie bar pulling from 0-LiniK . 7638. 9030Tie bar removal from 0Linie:mmmmmmmmEjector stroke: . 220 mmEjector force: . .400 kNLOCKING FORCEMax. locking1 .force .10500I,I12-9906-001-AA105L Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil
8/122.9Technical dataEvolution 105 DLShot unitNITROGEN SYSTEM INTENSIFIERFilling quantity: . 65 dmaMax. idle pressure: . 160 barArea ratio:. 1 : 2,44Stroke: . 170 mmNITROGEN SYSTEM ACCUMULATORFilling quantity: . 195 dm 3Max. idle pressure: . 160 barMax. pressure accumulator charged: . 200 bar(PLUNGERCASTING POSITION ADJUSTMENTInjection force dynamic: . 398Injection force intensified: . 1096Plunger stroke: . 900Plunger diameter:. 3.25 - 5kNkNmminchCasting positions: . 0 I- 350 mmPLUNGER LUBRICATIONFilling quantity: . 10 dm 3 Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil12-9906-001-AA105L
Technical dataEvolution 105 DL9/122.10 Production dataPluger Diameterinch3.253.544.55Maximum Casting Volumecuin196227297375463Maximum Casting Weight AIlb17.6220.4426.6933.7841 .70Maximum Metal Pressurepsi2970125610 19607 15492 12549Maximum Projected Areasq in7992120152188SC D/105The maximum casting weight is calculated according to (DIN 22480) :/s x Plunger Stroke x Plunger Surface x Density (AI 2,5 kg/dm 3 )22.11 p/Q2-Diagram--13000tn 12000a.c11000Q)10000I.::s9000a:8000tn :e70006000 500004000tt ·0l0 3.25 v \\'3.5 11/I0 411I\\\: I 0 4.5 I\\ I t--- / 0r-.\\ / \\ . 11 10000012-9906-001-AA105LI0 3000sc D'105 sc D'140I/r"'v '\ 2000C/)1110000000 200000003000000040000000Flow Rate in (cu in/s)115 500000002 Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
10/12Technical dataEvolution 105 DL2.12 Noise level of the DCMSoundSources: the drive unit. during the casting process.Depends on: machine load during operation.Regulations: observe the local regulations.WARNING!If the noise em ission is higher than the permissible values thepersonnel must wear appropriate ear protectors!Measuring setup Casting process without metal (plastic plug). When casting with metal smallerpulse coefficients DLI eq (ca. 3dB) must be expected. Data are related exclusively to the DCM (without peripheral units). Measurements carried out according to DIN 45635 Section 1. Variations from the given values Leq and DLI eq are contingent to the operatingconditions tCyc, vi and vi Br.ResultsLeqA-rating equivalent continuous sound level pressure at the workingplace including the pulse coefficient . . . 79 dB(A)DLI eq pulse coefficient . . . . . . . . . . 5dBOperating conditionstCyccycling time . . . . . . . . 30sviplunger speed . . . . . . . . . . 5.0m/svi Brbraking velocity . . . . . . 1.0m/s Copyright 1999 BOhler D ruckguss AG , CH-9240 Uzwil12-9906-001-AA 105 L(
Technical dataEvolution 105 DL11/122.13 Peripheral unitsPlease take the technical details of peripheral units from the relevant instructionmanuals.2.14 EnclosuresChecklistDimension sheets:Die-casting machinePlatensShot unit12-9906-001-AA1OSL Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
12/ 12Technical dataEvolution 105 DL( Copyright 1999 BOhler Oruckguss AG, CH-9240 Uzwil12-9906-001-AA105L
Checklistpage 1/1Check list technical data I operating materialsCheck the following points according to check list:OK V The required amount of hydraulic fluid is available[J The required lubricant for the central lubricating system is available[J The required plunger lubricant is available[J The required nitrogen is availableD Lubricating grease for the die-casting machine is available[J Lubricating grease for the electric motors is available[JNotesDate: . . .GEB-17000-enSignature: . . .18.04.96 Buhler AG
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Preface1/4PrefaceBuhler Druckguss AG reserves all rights to this document and to the object thereof.Without the prior written permission of the Buhler Druckguss AG this document maynot, either in whole or in part, be reproduced, copied, or, in any form, in whole or inpart, made accessible to a third party, or be used for any purpose other than that forwhich it was made available to the recipient.These Operating Instructions include basic information on the design and operatingprinciple, the installation, startup, operation and maintenance of the machine andcontrol unit.(It is assumed that the operators are qualified and tra ined. For this reason, suchdescriptions as do not require any special knowledge have been omitted. Instructionsfor repairs that go beyond the normal maintenance and servicing, are not describedhere.This machine is built in compliance with the recognised safety engineering principles.In spite of this, inexpert use may entail hazards to the health and life of persons, ormay cause damage to property.CAUTION!Do not set the machine into operation before you have read and understood the entire instruction manual, in particular Chapter , Safety"!Non-compliance with the Operating Instructions will result in the lapse of warranty;this also applies to alterations or repairs to the machine without permission in writingfrom Buhler Druckguss AGin advance. Damage which is the result of inexpert handling,disregard of our instructions, or operating errors made by untrained personnel, cannever in any circumstances be charged to the manufacturer.Buhler DruckgussAG is only liable for direct person injury and direct property damagebased on the applicable product liability law if the machine is used within the areaspecified in these Operating Instructions, or in a contractually agreed application.Buhler Druckguss AG is not obliged to reimburse damage which is not direct result ofthe machine itself (exploitation losses, production downtime and profit drop as wellas other direct and indirect damage).Buhler Druckguss AG, Uzwii/Schweiz10-9906-000-AAOOCE Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
2/4PrefaceSoftwarePage Maker 6.5 Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil10-9906-000-AAOO
Preface0.1314Content of the machine documentationManual 1: Operating instructions safety technical data transportpreparing the site of installationenergy connectionsoperating materialserecting and starting upManual 2: Operating instructions design and method of function operating I programming settingmaintenancediagnosis I elimination of faultshydrailc diagrams spare parts customer specific accessoriesManual 3: Electrical diagrams electrical diagrams description of interfaces spare parts for the control system adjustment instructionsCertificates certificates for:- accumulators- pressure vessels- safety valves'10-9906-000-AAOO Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil
4/40.2PrefaceDesignation of the machine sidesRight hand sideDirection of metal flow Left hand side0.3AbbreviationsFollowing abbreviations are used in the operating manuals and on the screen: DCMDCIMMI Die-casting machineDie-casting installationMan Machine Interface Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil\10-9906-000-AAOO
Safety1/18(1SafetyContents10 1General110 21031.40 101Directed use300 0 0 0 0 0 0 00 0 0 0 0 0 0 0 o 0 0 00 0 0 0 0 0 0 0 0 0 0 o 03o o oo o oo o oo o o oooooo oo oo oo oo o o o oo o ooo oo ooooo o o oo oo ooo ooo o o o o o o o o o o 40 0 0 0 0 00 0 0 0 0 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 o 0 0 0 0 0 0 0 0 0 0 0 00 0 0 0 040 0 . o 0 0 0 0 00 0 0 0 0 O o 0 0 0 0 0 0 0 0 0 00 0 00 0 0 0 0 0 00 0 . 0 0 0 0 0 00 0 o ·Directions on protection of labour1041.4021.4 0310410 104. 4. 61.4.71.4.81.4.91.4.1 01.4.111.4.121.4 0 131.5Duty of Instruction0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0Symbol for safety of labour .1.40510 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .4.14General0 0 0 0 00 0 0 0 0 0 0 0 . 0 0 0 . 0 0 0 . 0 0 0 00 0 0 0 0 0 0 0 0 0 0 0 0 0. O o 0 0 0 0 0 0 . 0 o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 050 0 0 0 0 0 0 0 0. 0 0 0 0 0 0 0 0. 0. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 060 0 0 0 0 0 0 0 0 0. 0 . 0 0. 0 0 0 0. 0 0. 0 0 0 0 0 0 0 06Safety for operator and machine setter .Protective clothing for the personnelHazardous areas0 0 0 0 0 0 0 0 0 0 0 0 0 . 0 . 0 0 0 . 0 0 0 . 0 0 . 0 0 . 0 0 0 0 0 00 0 0 0 .Protective devices .Fencing60 0 0 o 0 . 0 0 0 0 0 0 0 0 0 0 0 0 o o 0 o 0 0 0 0 0 0 0 0 0 0 0 .7o 0 0 0 0 0 0 . 0 . o 0 . 0 0 00 0 0 0 0 0 o 0 . 0 07o o o o o o o o o o o ooo o oo oOOO oooo o o o o o o o o o oo o o ooo o oo o o o o o o o o 80 0 0 0 0 0 o 0 o 0 0 0 0 0 0 o 0 0 0 0 00 0 .Instructions for transportMachine Erection0 0 0 0 0 0 0. 0 0 0 00 . 0 0 0 0 0 0 00 0 00 0 o 0 0 o 0 0 0 0 0 0 0 0 0 .0 0 0 0 0 0 o 0 . o 0 o o 0 .0 0 .0 0 0 0 o 0 0 0 00 0 0 0 0 0 0 0 0 0 0 00 0 0 0 0 0 0 0 0 00 0 0 0 0 .Electrical Equipment0 0 0 0. 0 0 0 0 0 0 0 .Machine Initial StartupMachine Operation .0 0 0 0 0 0 0 . 0. 0. 0 0 0 .05.11. 5021.5.3Oo 0 0 0 0 0 0 0 .Mechanical maintenance .0 0 .890 0 0 0 . . 0 0. 0. 0 0 0 0 0 0 0 0 0 0 0 0. 0 0 0 0 0 0 090 0 0 0 0 0 0 0 0 o ·0 0 0 00.00 0 0 0 0 0.0 0 0 0 0 0 0 0 o o 0 0 0 0 .0 0 0 0.0 0 0 o · ·· 0 0 000 0 0 . 0 o o o o . 0 0 0 0 0 0 0 0 0 0 0 .1011120 0 0 0 0 130 0 0 0. 0 13Data safeguarding .Viruses0 0 .0 0Avoidance of accidents by careful maintenanceControl software .0 0 0 0 0 0 0 00 0 0 00 0 00 0 0 0 8o . o 0 oo 0 0 0 000 0 0 0 0 0 0 0 . 00 0 . 0 0 o 0 . 0 0 0 . 0 0 0 0 O oo 00 0 0 0 0 0 . o .Safety Concept for Control Systems of Machines .10 0 0 0 0 0 0 0 0 0 .0 0 0 0 0 0 0 . 0 . 0 . 0 . 0 0. 0 0 0 0 0 0 0 0 0 .0 . 0 0 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .Electrical maintenance50 . o 0 . o 0 0 0 0 0 0 o 0 0 130 o 0 o 0 0 o . 0 o 0 o o 0 .14(11-9906-000-AAOO Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil
Safety2/181.61.7Emissions . . . . . . . . . . . . . . 151.6.1Noise . . . . . . . . . . . . 151.6.2Emission of vapours and smoke . . . . . 151 .6.3Liquids that are detrimental to health and the environment. . 161.6.4Service water . . . . . . . . . 16Country Specific Standards . . . . 17SoftwarePage Maker 6.5 Copyright 1999 BOhler Druckguss AG , CH-9240 Uzwil11-9906-000-AAOO
Safety1.13/ 18GeneralThese operating instructions must always be kept close to the machine.1.1.1Duty of InstructionThe user is responsible for training and safety of operating personnel. Thus, it is veryimportant that the documentation is actually handed over to these persons.The machine user and operating personnel are obliged to note and to observe theinstructions in these operating instructions.The user is responsible for instructing the personnel as to the fire prevention measuresand adhering to the relevant rules and regulations .The user of the machine is obliged to observe the following regulations in order toobtain the highest possible standard of safety for the operating personnel at themachines.The machine should only be operated by persons who have been instructed and areaware of the dangers involved.Every person the in the company of the user who is concerned with the installation,setting into operation, machine setting and die changing, operating and maintenance(inspection , maintenance, repairing) of the DCM or DCI must have read andunderstood the complete instruction manual and in particular Chapter ,Safety".If personnel are employed who are not able to read , the owner of the machine mustcarefully point out all possible dangers to them and instruct them specially.The competences of the personnel regarding operation, machine setting and diechanging, programming and servicing of machine and control system must be clearlydefined and adhered to, so as to avoid any confusion of responsibilities related tothe aspect of safety.The user must make sure that his personnel is able to operate, set and service themachine and knows the safety instructions.The user is recommended to have this confirmed in writing by his personnel.It is recommended to consult BOhler personnel for instruction purpose.NoteBy "user" is understood whoever uses the machine for economic reasons. Theuser is not identical with the person who operates the machine.11-9906-000-AAOO Copyright 1999 BOhler Druckguss AG , CH -9240 Uzwil
4/ 181.2SafetySymbol for safety of labourThis symbol will be found near all references concerning safety of labourin this instruction manual and in connection with the relevant titles andcan mean "DANGER!"immediate danger to life and limb "WARNING!"possible danger of injury or life "CAUTION!"possible danger of injury, damage.Take notice of these references and act with necessary care in these cases. Pass onall instructions for safety of labour also to users. Besides the references in this manualalso the local regulations for safety and accident prevention must be observed.1.3Directed useBuhler horizontal die-casting machines are designed exclusively for the pressuredie-casting of aluminium, magnesium, zinc and copper alloys. Any use beyond thisscope is regarded as non-directed.The manufacturer can not be made liable for any damages that are a result of nondirected use. The user is the sole bearer of the risk for such damageThe observance of the conditions for installation, start-up, operation and maintenanceas instructed by the manufacturer are inherent with the directed use. Copyright 1999 BOhler Druckguss AG, CH-9240 Uzwil11-9906-000-AAOO
Safety1.45/18Directions on protection of labour1.4.1 GeneralThe machine should be operated only if it is in the faultless operational condition,and used conscious of safety and hazards and in accordance with the intendedpurpose. In addition, these operating instructions must be observed.The machine is built in keeping with the latest technological developments and inaccordance with current standards of safety of labour and operation. However, thereare dangers connected with these machines if they are not appropriately used byuntrained personnel or if they are not used as directed.The machine is equipped ex factory with safety devices . As long as the machine isused for its intended purpose these precautions conform to the current internationalstate-of-the-art as well as the accident prevention regulations generally in effect.These operating instructions include the safety rules for preventing accidents. Inaddition, all generally valid local safety instructions and safety rules do always apply.For all activities concerning setting into operation, operating, machine setting andservicing of the DCM or DCI the switching off procedures described in the operatingmanuals must be observed.All activities in connection with setting, repairing and servicing of DCM or DCI mustbe carried out exclusively with the DCM or DCI switched off and while it is at standstill.Every method of working by which safety at the DCM or DCI is impaired is forbidden .Wilful modifications and changes which impair safe operation of the DCM or DCI arenot allowed.Safety and protective devices must be kept in perfect working condition under allconditions. The removal, making ineffective or putting out of order of these devicesis strictly forbidden.Before starting up after repairing or maintenance work always make sure that allsafety devices have been installed.If malfunction occurs, immediately identify and eliminate the cause.By all means observe notices and danger signs, keep these clean , do not remove orcover them.11-9906-000-AAOO Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
6/18Safety1.4.2 Safety for operator and machine setterThe operator and machine setter are jointly responsib le for not letting persons workon the DCM or DCI who are not qualified to do so.The operator and machine setter are obliged to immediately notify any changeswhich impair the safety of the DCM or DCI.The operator and machine setter are obliged to wear clothing as prescribed (seeParagraph "Protective clothing for personnel").It is strictly forbidden for any persons to be within the hazardous area while at thesame time a person is operating the DCM or DCI at the operating unit.During machine setting the metal ladling unit must be switched off and secured.During machine setting with the cover of the casting cylinder open, never stand onthe piston rod of the casting cylinder. Danger of squashing!1.4.3 Protective clothing for the personnelThe personnel should wear eye protectors, gloves, headgear, good shoes andouterwear of robust material that is resistant to high temperatures.Inappropriate or wrong clothing can be a cause for burning.Observe the local regulations.1.4.4 Hazardous areasThe operating instructions refer to special dangerous areas. These areas of themachine are marked by using warning signs.The hazardous areas are explained under Chapter "Preparing the site of installation"and are briefly described hereafterThe moving elements of the DCM Toggle system:squashing and shearing points Die area:squashing points, high temperatures, metal spray Injection unit:squashing points and possibly metal sprayThe peripheral units(see the instruction manuals of the peripheral units) Spraying unit Extractor Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil11-9906-000-AAOO
Safety Metal ladling unit Trimming press, etc.7/18Accessing the die area is allowed only when the machine, spraying unit and extractorare switched off and secured.Safety-gate area when program selected "with/without safety gate" Program selection "with/without safety gate" is an extremely dangerouscondition . The user is therefore, under the obligation to fence in the safetygate area (see chapter "Errection/Setting into operation", paragraph "Fencing"). In addition to the fencing , also a splash plate, e. g. of steel plate, must bemounted against metal spray from the die.1.4.5 Protective devicesIn order to protect the personnel against hazards as described under Paragraph"Hazardous areas" the DCM is equipped with shields, covers, protection grids, safety gatesoperator anti-trap device etc. (see Chapter "Design and method offunction"). every peripheral unit is fitted with the necessary protective devices (seeinstruction manuals of the peripherals). the DCI should be safeguarded by a fencing (see paragraph "Fencing"). the user is responsible, to provide a protective device in the shot sleeve areaagainst possibly metal spray.1.4.6 FencingFences are protective devices which surround the hazardous area in such a manner,that these alone, or in connection with other parts, inhibit access to the hazardousareas from outside.Surmounting or passing through the fencing without aids must not be possible.Access to the safeguarded area must be exclusively via doors. The doors areinterlocked with the control system of the installation in such a manner, that accessto the hazardous areas is possible only in non-hazardous condition.For example of a DCM or DCI fencing see Chapter "Preparing the site of installation".11 -9906-000-AAOO Copyright 1999 Buhler Druckguss AG, CH-9240 Uzwil
Maschine-Type: Evolution 105 DL Year of construction: 2001 Technical data Order Number: 574 907 2.2 Machine type designation Maschine-serial Maschine-Number: . Manual 3: Electrical diagrams electrical diagrams description of interfaces spare parts for the control system adjustment instructions
