This pressure casting machine with 12 modules is used to produce rim of toilet bowl, wash basin, lid which is modern high pressure casting equipment which integrates comprehensive technology of water, electricity, compressor air, hydraulic and vacuum.
As the first choice for modern sanitary ceramic factory and favorite of client, it is mainly applicable to cast and form green rim of two piece toilet.
Its' advantage is: high output, low labor cost, energy saving and environmental protection, also it solves the problem of youth labor shortage.
The high pressure casting machine produces rim of water closet, it mainly includes the following parts:
- Main body parts;
- Hydraulic closing mold system;
- Pressurize casting slip system;
- Feeding and return slip system;
- Compressor air system;
- Vacuum demoulding system;
- Supply water system;
- Cleaning mold system;
- Electrical auto control system;
- Others customized device.
1. Suitable for producing different model rim of two piece toilet bowl, wash basin, lid.
2. Flexible for different capacity, low invest cost.
3. Machine advantage:
High auto control, low labor strength;
Small floor space with low building cost;
The machine chooses Siemen PLC 1500 series, can realize remoting control and fault eliminate, help factory to manage producing;
Choose Japan SMC pneumatic control system, Omron lighting control element, Germany IFM sensor, Hydraulic system adopts American Rexroth valve group, Germany Pepper Fuchs proximity switch, America Parker seal to make sure the machine stable running, reduce faults rate.
The machine adopts marine fluorocarbon paint, which has strong corrosion resistance in high temperature and high humidity environments.
| Capacity calculation, sample by 12 sets module type | ||
| Daily working time | 22.5 | Hours/day |
| 1350 | Mins/day | |
| Q'ty of module | 12 | 1 pcs of mould/module |
| Casting cycle | 30 | Mins |
| Daily output | 540 | pcs |
| Average manpower output | ||
| Q'ty of shift per day | 3 | |
| Manpower per shift | 4 | |
| Average manpower output | 45 | 45 pcs/man/shift; includes process of blowing-cleaning, polishing, hole punching, body turnover, rim sticking and handle the body up to trolley |
| No. | Items | Contents |
| 1 | Demoulding method | Horizontal opening and closing mold, demoulding by manual |
| 2 | Mould close method | mould close by hydraulic |
| 3 | Pressure of mould close | 80-120T |
| 4 | Accurate of mould close | ±0.25mm |
| 5 | Working pressure intensity of this system | 18-20Mpa |
| 6 | Pressure of low-pressure slip feeding | 0.15-0.2MPa |
| 7 | Pressure of hi-pressure slip feeding | 0.8-1.0MPa |
| 8 | Method to increase pressure for slip feeding | Hydraulic pressurize or pneumatic pressurize |
| 9 | Pressure of compressed air | 0.6-0.8MPa |
| 10 | Air consumption (/module) | 0.2M³/h/station |
| 11 | Pressure of water resource | 0.3MPa |
| 12 | Water consumption (/module) | 0.025M³/h/station |
| 13 | Quantity of mould | 12 sets resin working mould |
| 14 | Total casting cycle | 20~25min/cycle (adjustable) |
| 15 | Total install power | 19.55kw |
| 16 | Method of green body taking | By manual |
| 17 | Total weight with mold | 35-40T |
| 18 | Dimension | L: 11000mm W: 2920mm, H: 2880mm |
| Item No | Parts name | Brand | Remarks |
| 1 | PLC | Siemens | 1200-1500 Series |
| 2 | Touching screen | Kinco | |
| 3 | Pneumatic control cabinet | SMC | Integrated control |
| 4 | Pneumatic control elements | SMC | Air pipe, valve |
| 5 | Travel Switch | Schneider | |
| 6 | Proximity switch | Pepperl fuchs | |
| 7 | Water drop seperator | SMC | |
| 8 | Micro-mist seperator | SMC | |
| 9 | Cycle vacuum pump | Nash | |
| 10 | Speed control valve | SMC | |
| 11 | Cylinder | SMC | |
| 12 | Solenoid valve | SMC | |
| 13 | Reducing valve | SMC | |
| 14 | Electric elements | Schneider and Omron | |
| 15 | Safety curtain | Omron | |
| 16 | Hydraulic valve group | Rexroth | |
| 17 | Seal of hydraulic station | Parker |
Turn on the hydraulic cylinder of the slip booster system. The mold is clamped and compressed by the molding press cylinder to the origin position, and the operation program enters the standby initial state.
Casting
The slip is feed into the mold at low pressure through the casting pipeline, and automatically switched to high pressure casting after the cavity of the model is filled with slip. After the set time is reached, the casting stops, the slip master valve opens, and the slip booster releases pressure and automatically returns to the slip.
Mold de-moulding
The compressed air system and vacuum demolding system are activated, the main vacuum valve is opened, and the auxiliary demolding air valve is opened;
The mould opening is automatically by cylinder control to reduce labor strength.
Mould closing
When finished the de-moulding, the mold will close by hydraulic pressurize to begin the next casting cycle.
Working principle of hydraulic system
The toilet casting hydraulic system is composed of an oil tank unit, an oil pump motor unit, a hydraulic valve group and hydraulic accessories; the main pump adopts the double pump RZ5.1/3-45 of Hawe from Germany, which has low pressure, large flow and small high pressure. The use characteristics of flow, the use of smaller motor power to achieve high-voltage control of the system, save energy, and meet the requirements of the system.
The slip cylinder adopts the form of a hydraulic cylinder driving the slip cylinder, which realizes the purpose of a small flow system to control a large slip cylinder; the system is composed of an oil pump motor and hydraulic components.
| Working condition | ||
| Slip temperature | 35±2 | ºC |
| Absorption slip thickness | 8-9mm | 45mins |
| Casting workshop temperature | 30±2 | ºC |
| Relative humidity | 65±2 | ° |
| Air source pressure | ≥0.6 | Mpa |
| Water pressure | ≥0.3 | Mpa |
| Water condition for cleaning mold | 1 | μm |
| Water source filter | 10 | μm |
