Where is the boundary for the transformation of old machines to adapt to new molds

Where is the boundary for the transformation of old machines to adapt to new molds
Old machines can be modified in terms of interface, ejection, and temperature control, but not in terms of tonnage, stroke, and rigidity; The cost of cross-border transformation is often higher than replacing the machine.
Confirm three hard parameters first
The tonnage, pressure plate size, and maximum and minimum mold height determine whether the mold can be installed on the machine.
Insufficient tonnage, insufficient locking force, and uncontrollable parting surface flash. The size of the pressure plate is not enough, and the mold cannot fit in at all.
The mold height exceeds the range, and the pressure plate cannot be tightly pressed or closed. If any of these three conditions are not met, there can be no talk of renovation.
Removable parts
The interface flange can be modified. Adding transition plates or reprocessing flanges often costs between 10000 and 30000 yuan.
The top structure can be modified. Changing the length of the top pole and adding a transition top plate will cost 20000 to 50000 yuan.
The temperature control channel can be modified. Installing diversion blocks or modifying connectors costs 5000-20000 yuan.
Non modifiable parts
The tonnage of the machine cannot be increased through modification. The strength of the hydraulic system and frame is determined by design, and the cost of renovation is close to that of replacing the machine.
The mold opening stroke is limited by the length of the oil cylinder. Extending the stroke requires replacing the oil cylinder and frame, which is a huge amount of work.
The rigidity of the rack cannot be improved. After the fatigue of the old machine frame, elastic deformation will be transmitted to the casting size.
Economic evaluation of renovation
If the renovation cost exceeds 30% of the new machine price, it is recommended to replace the machine directly. The reliability of old machines is also declining.
The capacity improvement after the renovation is limited. Interface transformation does not change the pace, only solves the problem of 'can it be done'.
Xinfeng Mold will first conduct a machine test on the old machine adaptation project of the wheel hub mold, and then determine whether the transformation is worth it.
Common risks
The first issue is that the measured data is inaccurate. According to the drawings, the installation machine discovered a difference of 2-5mm in actual dimensions.
The second issue is the aging of the hydraulic system. After the renovation, the pressure establishment is slow and the filling process is unstable.
The third issue is the lack of safety devices. The safety interlock of the old machine may have failed, and the risk is higher after modification.
Transformation process
First, conduct surveying and mapping, then come up with a renovation plan, then process transition parts, and finally perform air circulation and mold testing.
Empty loop no less than 20 times, confirm no interference. Perform X-ray and dimensional inspection on the first prototype.
The modified parameters need to be recalibrated and cannot use the original machine's parameter library.
Three checks before renovation
Verify the machine nameplate against the measured tonnage, verify the distance between the pressure plate and the pull rod, and verify the maximum and minimum mold height. All three items will be approved before discussing the modification plan.
The verification results should be documented in writing as an attachment to the renovation contract. This record is the basis for any adaptation disputes that may arise later on.
Practical tips
After the transformation, the mold needs to undergo a re verification of the parallelism of the mold, and the four point deviation should be controlled within 0.05mm before production.
The thickness and material of the transition plate should be calculated according to the weight of the mold. Thin plates will deform, while thick plates will affect the mold height.
Before the renovation, the hydraulic oil of the original machine should be sampled and tested. The deterioration of the oil will slow down the pressure response after the renovation.
Frequently Asked Questions
Q: Can the mold height be changed for old machines?
Answer: Transition plates can be added, but they are limited by the travel of the pressure plate.
Q: Can insufficient tonnage be modified?
Answer: No, it's close to the cost of replacing the machine.
Q: How much is the renovation cost?
Answer: The interface costs 10000-30000 yuan, and the top out costs 20000-50000 yuan.
Q: Will the production capacity increase after the renovation?
Answer: No, it only solves the adaptation problem.
Q: What should be done before the renovation?
Answer: Measure the size of the machine and verify three hard parameters.
Q: Do I need to test the mold again after the renovation?
Answer: Yes, the parameters need to be recalibrated.
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