Thick sheet vacuum forming machine

Technical Solution for Single-Head Thick Sheet Vacuum Forming Machine

(Yeed-3020)

Please contact us by:

Mobile: 0086-13867488227 (24 hours)

WeChat/WhatsApp: +86-13867488227

Email: yeedshower@qq.com

Website: www.yeedmachinery.com

We are professional vacuum forming machines and vacuum forming moulds manufacturer in Hangzhou city, China.

1,Equipment reference diagram

2,Equipment detail view

PLCtouch screen	Molding and clamping system
Heating furnace	Temperature Control Module
Heating furnace advance and retreat	servo motor

3,summary

1. This equipment is a semi-automatic single-station thick sheet vacuum forming machine, capable of adjusting the mold size according to the required product dimensions. The maximum effective mold area is 300×2000×600 mm, and the model designation is Yeed-3020. Key features of this machine include a well-designed structure and user-friendly operation, making it ideal for vacuum forming of medium-to-large plastic components.

2. The electrical control system employs a high-definition industrial touch control panel from a well-known PLC brand, integrated with intelligent temperature control algorithms, and features a comprehensive HMI (Human-Machine Interface). After configuring the relevant production parameters on the touch screen, operators simply load materials manually; all other operations are then completed automatically.

3. Application: Suitable for acrylic, ABS, HDPE, TPU, TPE, PP, PET, PS, HIPS, PC, PE, PVC, EVA, composite materials, and various thermoplastic sheets with diameters ranging from 2–14 mm, which, after being heated and softened, are vacuum-molded using dies to produce a wide range of automotive and marine decorative parts, equipment housings, luggage cases, bathtubs, refrigerator inner liners, logistics turnover pallets, logistics staging pallets, and top/bottom covers for enclosed crates and other packaging products.

4,process flow

Manual feeding → Material pressing (automatic) → Automatic heating via upper and lower heating furnaces (automatic) → Plate drying to prevent sagging (automatic) → Automatic withdrawal of upper and lower heating furnaces → Blowing (optional) → Upper mold stage ascent (automatic) → Vacuum forming (automatic) → Cooling (automatic) → Reverse blowing for demolding (automatic) → Lower mold stage descent (automatic) → Upper material pressing frame ascent (automatic) → Manual material retrieval completed.

5,Performance

Features:

1. The entire unit employs PLC control and is equipped with a high-definition touch screen as the human-machine interface; all time parameters can be configured and monitored via the touch screen. The device features diagnostic and file backup capabilities, and the touch screen provides real-time display of fault information and troubleshooting measures, ensuring ease of operation and maintenance.

2. Pressing System: Equipped with the latest automatic wellhead flipping pressing mechanism, the pressing frame automatically adjusts to the wellhead size. The system features a fully aluminum movable wellhead, allowing mold replacement to be accomplished simply by adjusting the size according to the required dimensions—ensuring simple, rapid, and safe mold switching. A safety light barrier is installed within the operating area, completely isolating the forming zone from the operator; mechanical operation only proceeds after the operator presses the confirmation button.

3. Heating furnace: Utilizes carbon fiber S-shaped heating tubes for instantaneous temperature rise; each heating unit is equipped with short-circuit overload protection. The heating tubes feature high thermal conductivity, extended service life, and rapid heating capabilities. (Power is supplied during sheet metal heating; when heating is not required, the electric furnace automatically disconnects to save energy, and the heating elements have a service life exceeding 5,000 hours.) The furnace frame is constructed from 304 stainless steel via encircling welding and is fitted with stainless steel cover plates to prevent high-temperature corrosion and protect the molds from dust deposition.

4. Heating plate temperature control: The Shanghai Aoyi temperature control adjustment module employs a one-to-one independent control system to regulate the temperature of each heating unit, ensuring precise temperature regulation, user-friendly operation, and a significant increase in product yield rate. All temperature settings can be adjusted via the touch screen, and temperature profiles for previously used molds can be saved for easy reuse in future operations.

5. Elevator mechanism of the heating furnace: A variable-frequency motor drives the rack via synchronous drive, ensuring rapid and smooth ascent and descent. The lower furnace is equipped with a precision-reduction cylinder; in the event of a malfunction or power failure, the furnace can be instantly retracted to prevent material sheets from falling and damaging the furnace. Additionally, if the descent of the material sheets falls below a preset safety height, the furnace will be forcibly retracted.

6. Mold Stage: The lifting and lowering of the mold stage is controlled by a branded servo motor, which offers advantages such as precise positioning and rapid startup. The lifting position and speed of the mold stage can be freely adjusted via the touch screen; additionally, a support plate function can be configured to keep the mold parallel to the well opening, facilitating the placement of steel sheets.

7. Anti-sagging system: Employs Omron's infrared detection to monitor sagging of the sheet material; during the sheet baking process, the system automatically supports the sheet if sagging occurs.

8. Product Blowing: This machine employs a molded sealed chamber; after the sheets are heated, a precision gas control valve is used to blow air. By setting specific parameters, the system can automatically control the blowing height, ensuring uniform thickness across the product.

9. Vacuum forming: Utilizes a 140 vacuum pump with a rapid large vacuum valve, combined with a secondary small vacuum adjustable valve for forming.

10. Product Cooling: The product is rapidly cooled and set by six built-in dual-port fans and water atomization nozzles integrated into the equipment.

11. This equipment features an automatic touchscreen display for fault detection, facilitating production and maintenance.

6,technical description

1. The machine primarily consists of the frame, the forming device, the heating device, the gas control system, and the electrical control system.

2. Body: Constructed from welded or assembled steel structural profiles, designed for the installation of shaping, heating, and auxiliary devices. The overall steel structural frame provides sufficient strength and rigidity. All metal surfaces have undergone anti-corrosion treatment and are coated with a base layer of anti-corrosion paint; standardized and universal components are employed in the structure to facilitate subsequent maintenance and enable easy replacement of all parts.

3. Design Philosophy: The design is minimalist, rational, and user-friendly, adhering to the principles of ergonomics (ample operating space, appropriately sized handles, and optimal working height) as well as the *Guidelines for Safety Design of Electrical Equipment*. The design facilitates maintenance, enabling easy replacement of all components. The construction and component s0009ion incorporate universal and standard parts, allowing manufacturers to perform timely maintenance. The overall equipment design ensures that no damage is inflicted on tooling components during operation, thereby guaranteeing stable and reliable equipment performance, free from vibration or crawling phenomena.

4. Molding device:

1) Mold Base Platform: Constructed by welding steel sections and steel plates, the mold base platform is vertically driven by a variable-frequency electric gear system (integrated unit), with a load capacity of ≤1500 kg. To ensure smooth operation, the platform drive employs synchronous drive via a variable-frequency motor, gear guide columns, and electric actuators; the setting of lifting parameters and speed adjustment are all performed via a touch screen. This mold base platform design significantly enhances the dynamic balance of the mechanism's motion, thereby extending the service life of the equipment. When the opening dimensions of the mold change, no need exists to redesign the mold window panel within the equipment's adjustable range.

2) The upper mold features an electric lifting mechanism, allowing users to directly configure lifting parameters and speed via the touch screen. It supports multi-stage speed drive operation, ensuring convenience and safety while reducing labor hours.

3) Clamping rack assembly: Used for mounting the clamping frame; this movable structure is directly driven by a power cylinder. The clamping frame provides sufficient rigidity and strength to secure the clamping frame and ensure consistent clamping performance. When the mold opening dimensions change, the clamping frame in both longitudinal and transverse directions can be continuously adjusted, eliminating the need to redesign the clamping frame.

4) Cooling system: equipped with cooling fans whose air outlet direction can be flexibly adjusted, as well as multiple atomization cooling devices, primarily used for molding control or product cooling.

5. heat unit

1) The system employs a dual-sided heating configuration, primarily consisting of a halogen heating element or a carbon fiber heating element, a support frame for mounting the heating element, and a ceramic joint, all of which are controlled by an electric synchronous drive. The halogen heating element offers the following characteristics: synchronous light-heat conversion, rapid preheating capability, high heat penetration, excellent reflective performance, automatic power cutoff when not in operation, and significant energy savings.

2) The heating element employs high-temperature-resistant wires, and the heating tube is connected to the stainless steel support plate via a ceramic joint, facilitating the replacement of the heating element.

3) Temperature control is achieved using a multi-channel electronic voltage-regulated temperature control module, which ensures accurate display and control performance. Each independent temperature control unit regulates the heating element, featuring voltage stabilization functionality that remains unaffected by voltage fluctuations, as well as a backup/recipe storage capability.

Comparison of heating tube layout with industry peers

The Junjing product is shown in the figure below, and the competing manufacturers' products are shown in the following figure. The Junjing product is shown in the figure below, and the competing manufacturers' products are shown in the following figure.

6. Air circuit system

1) It consists of a positive pressure gauge, various gas pipelines, assorted conventional valves, and proportional pressure valves.

2) The air line inlet is equipped with an air filtration device (air combination switch).

3) Except where structurally required, all pressurized pipelines shall utilize high-pressure pipe connections, with their layout being neat and aesthetically pleasing.

7. vacuum and sub-atmospheric system

1) These primarily consist of vacuum piping, vacuum pumps, vacuum chambers, vacuum tanks (designed to maximize storage capacity), and dual vacuum corner seat valves; the vacuum flexible hoses connecting to the mold interface of the mold base utilize large-diameter, flexible steel wire hoses.

2) A single 140 m³ vacuum pump is employed to ensure sufficient vacuum capacity and continuous vacuum operation for large molds; the unit size shall be adjusted according to the vacuum demand based on the dimensions of the product molds.

3) The vacuuming process features both rapid and slow vacuuming modes, facilitating adjustments to the molding process and ensuring the reliability of product molding.

8. Electrical and computer control systems / Safety facilities

1) The system incorporates multiple protective measures, and interlocking protections are provided for any actions that could potentially conflict with one another.

2) The mold safety door protection sealing device employs a manual engagement and manual locking mechanism; if the safety door fails to close fully or does not close, other operations cannot be initiated, thereby enhancing the equipment's safety factor.

3) The main electrical control system employs an imported PLC, utilizes a touch screen as the HMI (human-machine interface), and features a Chinese-language interface. The machine is equipped with button controls as well as the ability to set and modify parameters for all processing stages, ensuring ease of operation and maintenance.

4) The machine operates in either manual or automatic mode, with all settings and operations controlled via the touch screen; once the operator has properly positioned the sheet metal, they can start the machine in automatic mode to complete one forming cycle; manual operation is primarily used for mold changing or sample setting.

5) The distribution cabinet incorporates protection circuits, including overcurrent, overvoltage, undervoltage, short-circuit, and overload protection. The heating elements are equipped with a fuse protection mechanism. For safety concerns that could pose hazards to the system or workpieces, warning labels or supplementary textual descriptions are provided. A 10% spare space is reserved within the control cabinet for future modifications; the distribution cabinet is also installed with a filter grille and a protective cooling fan.

6) A safety photoelectric sensor (safety light barrier) is installed in the molding operation area to prevent the pressure frame from descending during normal operation; if the pressure frame in the molding operation area is touched by personnel or obstacles, the operation shall be immediately halted, thereby ensuring the personal safety of operators and observers.

7) All fixed cables and external wires of the power distribution box shall be concealed within cable trays to facilitate access for inspection and repair; if this is not feasible, flexible conduits shall be used for securing.

8) The "Emergency Stop" function forcibly cuts off the power supply to the equipment to ensure that no hazardous conditions arise during an emergency stop.

7,Equipment Advantages

1. Molding System: Both the upper and lower molds are servo-driven, eliminating the influence of pneumatic pressure; this ensures smooth mold closing speed and high mold closing precision.

2. Heating System: Equipped with a newly customized high-power S-type medium-wave tube, ensuring uniform heating and reducing baking time by one-third compared to conventional systems.

3. Vacuum system: features a large-capacity dual-tank design paired with optimized vacuum piping, enabling the application of negative pressure required for the stretching of high-difficulty products.

4. Tablet pressing design: A completely new tablet pressing structure that allows for quick die replacement in just 15–20 minutes, eliminating the need for additional template window welding.

5. Bubble generation feature: employs a multi-point dispersion approach to ensure uniform bubble formation;

6. Anti-sagging feature: Equipped with an infrared anti-sagging function; the anti-sagging height is scientifically designed, ensuring easy operation even with larger heating plates.

8,Key Equipment Parameters

9,Main components of the equipment

10,Applicable Environment for the Equipment

1. The equipment operates normally within a temperature range of-5 °C to 34 °C.

2. For equipment placement, it is recommended that the ceiling height of the workshop be 5.5 m, and that at least 1.5 m of clearance be maintained on the feed side.

3. The equipment may be installed on upper floors, provided that the floor load capacity meets the specified ground load requirement of 1 ton/m².

11,Supporting equipment

12,Relevant preparations prior to equipment installation and commissioning (provided by the customer)

1. Unloading: Given the wide width of the equipment, two forklifts must operate simultaneously from opposite sides, or a crane may be used.

2. Water: A faucet must be installed around the equipment (the equipment is recirculated within the chiller and does not discharge externally; when the water level in the chiller becomes insufficient, the system will automatically replenish the water without requiring manual intervention).

3. Power supply: three-phase, five-wire system, 380 V; power rating approximately 150 kW; 70 mm² copper-core cable is recommended.

4. Air: 1-inch compressed air port, pressure range 0.6–0.8 MPa.

5. Molds: To be prepared and commissioned according to the requirements.

6. Materials: For use in specimens; it is recommended to prepare an adequate quantity.

13,Detailed list of spare parts included with the equipment

14,Detailed Equipment Delivery Documentation

15,after-sale service

No advanced equipment can exist without the need for service; more precisely, an excellent product should be accompanied by excellent service. Our company adheres to the philosophy that "first-class service is our paramount priority," and we are committed to safeguarding the core interests of every user. To this end, we uphold the following four service commitments:

1. One-Year Warranty & Lifetime Service: We commit to providing a one-year full-unit warranty on all equipment sold, commencing from the date of activation. Within this one-year period, should any equipment failure arise from quality issues, our company will provide free replacement of parts and repair services; additionally, we offer lifetime warranty services for a fee.

2. Free Installation and Commissioning: We guarantee that professional technicians will be dispatched to install and commission the equipment we sell at no additional cost; furthermore, our after-sales service team consists of highly skilled engineers, ensuring that the services you require are provided promptly and effectively.

3. Rapid Response & Emergency Repair: We commit to providing feedback within 2 hours of receiving a service request, and dispatching a service technician to your company for repair within 48 hours; to effectively safeguard your production needs, we also provide emergency repair services within 24 hours.

4. Regular follow-ups and free training: We commit to conducting regular or request-based free follow-ups on your equipment's operating status, as well as providing technical training for your technical personnel, ensuring your equipment operates optimally.

The above outlines the technical solution for our company's Yeed-3020 single-head thick-sheet thermoforming machine. Should you have any questions, please feel free to contact our marketing consultants at any time. Our company is committed to providing you with premium equipment and services to help you realize your ambitious goals!