TRAINING ON TRAINING ON EMBOSSEMBOSS MACHINEMACHINE

PARTSPARTS

AndAnd

FUNCTIONSFUNCTIONS

EMBOSSEMBOSS MACHINEMACHINE

PARTSPARTS

AndAnd

FUNCTIONSFUNCTIONS

AIR CYLINDERAIR CYLINDER

Air cylinderAir cylinder – pneumatic cylinder – pneumatic cylinder

uses air to move by compression. The types that U-PAK commonly used is uses air to move by compression. The types that U-PAK commonly used is the SDAS and SDADS series.the SDAS and SDADS series.

CODECODE

SDA(D) S - 20 X 30 - BSDA(D) S - 20 X 30 - BMODEL MAGNET BORE SIZE STROKE ROD TYPEMODEL MAGNET BORE SIZE STROKE ROD TYPE

SDA – SDA –

Double actingsDouble actings

SDAD – SDAD –

Double rod and actingsDouble rod and actings

SSA – SSA –

Push typePush type

STA – STA –

Pull typePull type

S – With S – With magnetmagnet

Blank – Blank – Without Without magnetmagnet

BLANK – Female BLANK – Female threadthread

B – Male threadB – Male thread

N – No thread N – No thread

PARTSPARTS

1 – back cover1 – back cover

2 – body2 – body

3 – piston and rod3 – piston and rod

4 – C clip4 – C clip

5 – front cover5 – front cover

3 – SDAS series3 – SDAS series

3a – SDADS series3a – SDADS series

FUNCTIONFUNCTION

Moves the mould and plug/air box.Moves the mould and plug/air box.

Moves upper and lower heat bars.Moves upper and lower heat bars.

Press down the punch mold to make the Press down the punch mold to make the sprocket holes.sprocket holes.

Push the material at the punch section to Push the material at the punch section to have stable “E & F” measurement.have stable “E & F” measurement.

Press the material on the feeder section to Press the material on the feeder section to stabilize “P” dimension .stabilize “P” dimension .

MAINTENANCE AND CAREMAINTENANCE AND CARE

Needs to be lubricated.Needs to be lubricated.

Longer use makes the inner parts dirty. Longer use makes the inner parts dirty. Must be cleaned occasionally to prevent Must be cleaned occasionally to prevent premature damage.premature damage.

Clean inner parts with soap.Clean inner parts with soap.

Don’t use thinner when cleaning the inner Don’t use thinner when cleaning the inner parts because it will cause damage to the parts because it will cause damage to the shaft seal and o-ring.shaft seal and o-ring.

SOLENOID VALVESSOLENOID VALVES

Has coil that actuates the valve.Has coil that actuates the valve.Blocks the flow of water from the cooling Blocks the flow of water from the cooling system to the form cooling bar when actual system to the form cooling bar when actual temperature is below the Set temperature.temperature is below the Set temperature.Un hold the water when the actual temperature Un hold the water when the actual temperature is higher than the Set temperature.is higher than the Set temperature.

PARTSPARTS

1.1. Armature Armature assemblyassembly

2.2. Armature with Armature with springspring

3.3. CoilCoil4.4. BodyBody5.5. CoverCover6.6. NutNut7.7. Body cover / Body cover /

fixing platefixing plate

SOLENOID VALVESSOLENOID VALVES

Solenoid valve activates when the PLC sends Solenoid valve activates when the PLC sends signal to the solenoid through the relay. Then signal to the solenoid through the relay. Then air is released from the valves to be able for the air is released from the valves to be able for the cylinders to perform its function. Heatbar cylinders to perform its function. Heatbar section, form mould section, punch mould section, form mould section, punch mould section, feeder section and airbox/plug section.section, feeder section and airbox/plug section.

PARTSPARTS

1.1. End coversEnd covers2.2. coilcoil3.3. Pilot body Pilot body

with manual with manual overrideoverride

4.4. Cylinder bodyCylinder body5.5. PinsPins6.6. Armature with Armature with

springspring7.7. pistonpiston

SwitchSwitch

FUNCTIONFUNCTIONA device used to interrupt or re-establish the flow A device used to interrupt or re-establish the flow

of electricity in a circuit.of electricity in a circuit.

A mechanical switch that performs automatically A mechanical switch that performs automatically under prescribed conditions.under prescribed conditions.

A drawback of such switch is that when it is A drawback of such switch is that when it is opened, it induces a spark (arcing) which opened, it induces a spark (arcing) which creates high temperatures that can damage creates high temperatures that can damage the switch. the switch.

Arcing can be prevented by faster switching with Arcing can be prevented by faster switching with the use of an electronic switch.the use of an electronic switch.

RELAYRELAY

FUNCTIONFUNCTIONAn electrically controlled switch that is used to open and An electrically controlled switch that is used to open and

close an electric circuit. close an electric circuit. Actuated by a solenoid, consist of a coil with an Actuated by a solenoid, consist of a coil with an

enclosed fixed iron core and nearby movable enclosed fixed iron core and nearby movable armature, when the coil is energized, the armature is armature, when the coil is energized, the armature is attracted to it, the resulting motion is then used to attracted to it, the resulting motion is then used to open or close the relay circuit.open or close the relay circuit.

Many types of relays have been designed for various Many types of relays have been designed for various applications.applications.

Like : circuit breaker, computer, electric bells, telegraph Like : circuit breaker, computer, electric bells, telegraph systems, and electronic equipmentsystems, and electronic equipment （（ PLCPLC ， ， Servo Servo control)control)

A servomechanism, or “servo” for short, is an automatic A servomechanism, or “servo” for short, is an automatic control device.control device.It uses mechanical motion or position rather than electric It uses mechanical motion or position rather than electric or electronic signals to measure the changes requiring or electronic signals to measure the changes requiring control.control.Types of servo maybe classified according to the Types of servo maybe classified according to the manner in which the actuating signal is used to control manner in which the actuating signal is used to control the output, the signals at various parts of the system are the output, the signals at various parts of the system are all continuous function of time as, for example pitch all continuous function of time as, for example pitch regulation of emboss machine.regulation of emboss machine.

SERVOMECHANISMSERVOMECHANISM

SENSORSSENSORS

FUNCTIONFUNCTIONA.A. MAGNETIC SENSORMAGNETIC SENSOR

- Sends signals to the PLC to be able the - Sends signals to the PLC to be able the machine to run in automatic mode.machine to run in automatic mode.

B.B. PHOTO-ELECTRIC SENSORPHOTO-ELECTRIC SENSOR

- signals the motor to rotate, when the photo-- signals the motor to rotate, when the photo-electric light is interrupted during operation.electric light is interrupted during operation.

C.C. THERMO SENSORTHERMO SENSOR

- senses the temperature of the heatbar then - senses the temperature of the heatbar then sends it to the thermo controller.sends it to the thermo controller.

CONTROLLERCONTROLLER

A specialized type of clock. Can be used to control the sequence of an event A specialized type of clock. Can be used to control the sequence of an event or process.or process.

used to count the holding time of heatbars. Once the time set has been used to count the holding time of heatbars. Once the time set has been reached it will be releasedreached it will be released

TIMERTIMER

countercounterIn digital logic and computing, a In digital logic and computing, a countercounter is a device which stores (and is a device which stores (and

sometimes displays) the number of times a particular event or sometimes displays) the number of times a particular event or processprocess has occurred, often in relationship to a clock signal. In practice, there has occurred, often in relationship to a clock signal. In practice, there are two types of counters: are two types of counters: up counters which increase (increment) in value.,and down counters which decrease (decrement) in value.

Up counter is the type that is installed on the emboss machine which counts the number of embossing process which is needed to verify the length of the carrier being produced. Once the preset value reached the alarm will be turned on and the process stops and will continueonly once the reset button has been pressed.

Servo controlServo control unitunit

Servomechanism’s main control which gives signals to the servo motor.Servomechanism’s main control which gives signals to the servo motor.

PLCPLCProgrammable controller, responsible for the automatic operation of the emboss Programmable controller, responsible for the automatic operation of the emboss

machine. Output signal is set with the use of a computer machine. Output signal is set with the use of a computer

PITCH CONTROLLERPITCH CONTROLLERUsed to send signal to the servo control unit how long will be the movement of servo depending on the value being Used to send signal to the servo control unit how long will be the movement of servo depending on the value being

set. set.

Used to monitor and control the temperature of the Used to monitor and control the temperature of the heatbars and the form/die cooling block.heatbars and the form/die cooling block.

Two types used :Two types used :A. FY-400-1010(A. FY-400-1010(TAIETAIE) / MC-N2438-1010(maxthermo)) / MC-N2438-1010(maxthermo)

- used for cooling (Form) - used for cooling (Form) B. FY-400-2020 (B. FY-400-2020 (TAIETAIE) MC-N2438-2020(maxthermo)) MC-N2438-2020(maxthermo)

- used for heating (Heatbar)- used for heating (Heatbar)**Each controller can be used on both applications but much better Each controller can be used on both applications but much better

to follow for accurate control of temperature.to follow for accurate control of temperature.

Thermo-controllerThermo-controller

AA BB

PRESSURE, GAUGEPRESSURE, GAUGE

PRESSUREPRESSURE- A force measured in terms of its distribution over an area of - A force measured in terms of its distribution over an area of

opposing force, this is expressed as force (F) divided by unit of area (A) of the opposing force, this is expressed as force (F) divided by unit of area (A) of the surface area to which the force is applied.surface area to which the force is applied.

Gauge PressureGauge Pressure- measured with respect to air pressure, in the international system - measured with respect to air pressure, in the international system

of units. Pressure is given as kilograms per square meter (1kg/mof units. Pressure is given as kilograms per square meter (1kg/m²) = 0.20481614 ²) = 0.20481614 lb/ft².lb/ft².

Pressure gaugePressure gauge- A device used to measure the pressure of air supplied to the - A device used to measure the pressure of air supplied to the

cylinders (heatbar, form, plug/airbox)cylinders (heatbar, form, plug/airbox)

MACHINE PROTECTIONMACHINE PROTECTION

FUSEFUSEThe electrical fuse is a device placed in an electrical circuit to The electrical fuse is a device placed in an electrical circuit to

avoid overload. It usually contains a thin strip of metal that melts and avoid overload. It usually contains a thin strip of metal that melts and breaks when a current above a certain amperage passes through it.breaks when a current above a certain amperage passes through it.

CIRCUIT BREAKERCIRCUIT BREAKER

A switch that performs automatically under prescribed A switch that performs automatically under prescribed conditions.conditions.

It is important that a fuse or other circuit breaker control an overloaded It is important that a fuse or other circuit breaker control an overloaded circuit in order to avoid damage to the systemcircuit in order to avoid damage to the system

BBAA

Regulates the pressure supplied to the emboss Regulates the pressure supplied to the emboss machine.machine.Standard for the emboss machine is 7kg/cmStandard for the emboss machine is 7kg/cm² and ² and above.above.The BFR series has water/oil separator and filter(40The BFR series has water/oil separator and filter(40µµ filtering grade). Used in main supply. AR series is filtering grade). Used in main supply. AR series is used in pressure control of heatbar, form and airbox.used in pressure control of heatbar, form and airbox.

AIR REGULATORAIR REGULATOR

Steps down the supply voltage from 220 volts AC to 24 volts DC.Steps down the supply voltage from 220 volts AC to 24 volts DC.

The source of the emboss machines inner components like relays and The source of the emboss machines inner components like relays and solenoid valves is 24 volts dc. solenoid valves is 24 volts dc.

POWER SUPPLYPOWER SUPPLY

OPTO-ELECTRONIC SCALEOPTO-ELECTRONIC SCALE

Device used in measuring the length of vertical movement of the punch section Device used in measuring the length of vertical movement of the punch section prior to p2 adjustment. Length movement size can be seen on the opto-prior to p2 adjustment. Length movement size can be seen on the opto-display.display.

A reference to a source of electrical power. A device or system that supplies A reference to a source of electrical power. A device or system that supplies electrical or other types of energy to an output or load. electrical or other types of energy to an output or load.

EXAMEXAM1.1. State the two types of cylinder that is commonly used in U-pakState the two types of cylinder that is commonly used in U-pak

2.2. What are these?What are these?

3. What does this part do?3. What does this part do?

4. What the three different types of sensors4. What the three different types of sensors