Fully automatic high pressure forming up to 1000 x 500 mm.
The fully automatic high pressure forming system PAMK 1000 is suitable for the precise and highly efficient forming of films up to an XXL forming area of 1,000 x 500 mm, 12 mm material thickness and a forming height up to 300 mm.
|Max. forming area||1000 x 500 mm|
|Max. forming height||300 mm|
|Closing speed||Can be programmed as required|
|Cycle time/indexing time||Depending on material and component geometry|
|Forming pressure||max. 150 bar|
|Low pressure compressed air (deforming aid)||6 – 10 bar|
|Repeatability||+/- 0.7 mm (depending on the material and component geometry)|
|Forming tool temperature up to||150° C|
|Film thickness||0,05 – < 12 mm|
|Closing speed||Can be programmed as required|
|Rated power||160 kW|
|Rated current||170 A|
|Fuse protection||240 A|
|Operating voltage||3 x 400 V|
Space required (incl. hydraulic unit)
The following process steps form a typical example for this series. However, you can select the system that optimally matches your specific requirements from a number of different variants.
PAMK 400 and PAMK 1000 are loaded using film magazines (rotary table magazine or sliding magazine). The supply of film can be topped up without interrupting the operating cycle. The films are placed fully automatically on the film pallets.
The supply of film in the magazine permits sustained operation without the continuous presence of the operator. Visual and acoustic signals indicated when the supply is running low.
All production-related data can be quickly and straightforwardly entered or retrieved from the database using an ergonomic touch-screen controller. The in-house programming of the control panel software provides a high level of flexibility and individual adaptability. An integrated modem permits the reliable remote maintenance of your system by our team.
To optimise the process and quality assurance, as an option the system can be equipped with an infrared camera. With the aid of the related thermal images, the temperature and the distribution of the heat can be checked prior to forming. In this way consistent quality of the forming result is ensured.
The fully automatic systems are each equipped with 3 heating stations. The first two stations are used to preheat the films. In the main heating station the film surfaces are specifically heated with the aid of independently regulated heating elements. During this process heating is from the top as well as from the underside. The non-contact heating process is crucial here: as a result it is also possible to process coated, specially structured or transparent films delicately.
In addition it is also possible to heat the forming tool. This feature prevents, if necessary, excessively quick cooling of the film and is crucial for the precise moulding of the component geometry.
In the forming station the heated films are formed without contact using high pressure (PAMK 400: up to 300 bar, PAMK 1000: up to 150 bar). In this way material compaction with high surface density and stability is achieved, the surface structure and appearance are also retained.
The build up and relief of the pressure as well as the inflow speed during this process areindividually regulated. Homogeneous pressure distribution produces extremely sharp-edge parts and also makes possible undercut film contours.
PAMK series systems permit cycle times between 10 and 15 seconds. Tools, products and formats can be quickly and straightforwardly changed.
The product is cut out of the formed film in the punching station. Due to the innovative dual vertical cutting tools, even difficult cutting contours can be realised. In the first step break-outs or parts of the outer contour are cut. The second step undertakes the rest of the cuts and at the same time releases the formed film part from the carrier.
The finished parts are automatically removed from the punching station with the aid of a suction gripper. Optionally it is also possible to integrate a further punching module with a horizontal cut.
Depending on the requirement, the finished components can be set down in transport boxes or on conveyor belts to suit the specific customer. A sorting function is also possible. The film residue left over after punching is removed from the pallet using an ejector.
Equipment and peripherals
You can select the system that best matches your product portfolio from a number of different variants. You will find an overview of the possible equipment here.
As a system provider we also provide high pressure compressors perfectly matched to your system along with appropriate air Treatment.