IMD GRAPHIC MACHINE

In Mold Decoration Application
V-222DHCG MODEL

IMD V-222DHCG ZMD offers two models of the Graphics Machine
for the IMD applications, as follows:

1. The model V-222DHCG: this model is equipped with top moveable heater platen and bottom shuttle heater platen. The heaters can be equipped with 58 independent heat zones, microprocessor controlled, on 24"x24" forming area.

2. The model V-223DHCG: this model is equipped with top moveable heater platen and bottom shuttle heater platen. The heaters can be equipped with 87 independent heat zones, microprocessor controlled, on 24"x36" forming area.

     Any of the ZMD machines for the IMD applications have been design with special care, to provide full accuracy in terms of registration and repeatability. The specifications as below are of the V-222DHCG, our top of the line, bestseller machine for the IMD application.

     The V-222DHCG has been equipped with many additional features, to make the machine the most advanced of its kind. As a matter of fact, as far as we know, this is the only dedicated machine has ever been developed for the IMD (In Mold Decoration) applications, For vacuum forming of pre printed plastic sheets, with high registration accuracy and repeatability.

     Due to obvious reasons, the information below represents partial details only, while some other very important information is not listed at all.

     ZMD's Graphic Machine was designed to work with any thermoplastic material, but especially to form Polycarbonate films and sheets. Among its unique features:

Heavy-duty tubular steel construction.
Heating area: 24"x24". Custom forming sizes are available.
Solid-state electronics.
Maximum draw: 6" depth. Bigger draw is available.
The vacuum pump is modular design BUSCH R5 series rotary vane vacuum pump, single stage, air cooled, quiet operation and direct driven pump to provide end vacuum of 29.9 Hg Inches
An adjustable pneumatic clamping frame that provides 100% registration of plastic sheets.
Full control through the control panel on the movement of the bottom platen, and upper platen enables dead lock during its movement up or down for excellent stability.
This machine will enable control of the heating cycle by all possible means:
1. Sag.
2. Time.
3. Power Percentage
4. Sheet Temperature.
5. Thermocouples and PID Loops.
Machine is equipped with top and bottom heater platens. The top heater platen travels up and down, and is equipped with 50 Zones, each one is equipped with thermocouples, and is independently microprocessor controlled.
For accurate registration of pre printed plastic sheet, repeatable and constant temperature is necessary to comply with the heat cycle. The PLC, with special PID modules and friendly interface software, provide fast, repeatable and accurate temperature measurement, with tolerance of +/- 2°F.
The bottom heater travels in and out and is equipped with 8 heat zones, all microprocessor controlled.
A Pyrometer measures the sheet temperature during the heating cycle for repeatable and accurate cycle.
Photo Electric Guard or Light Curtain (electro sensitive safety system for industrial machines), 24" height, has been installed at the Load Area. Whenever the Load Area is crossed (invisible light is broken) during machine operation, the machine will freeze any reachable moving parts. An alarm will sound. Once the object that crossed the guarded area moved out of the machine, the cycle will not be stopped, and production will continue.
Soft vacuum capability will insure forming with minimum stretch of the plastic without loosing the efficiency of the excellent vacuum capability for high definition parts.
All functions of the machine are controlled and monitored by programmable microprocessors.
All known vacuum forming techniques such as Drape Forming Top (Male Mold); Drape Forming Bottom (Female Mold); Snap Back- Vacuum etc. are available.
Machine has 26 TIMERS and COUNTERS. All functions and timers control such as Platen delay; Bottom and top timers; Vacuum delay etc. are available by the easiest way. Just a finger touch of the simplest and friendliest controller in the market.
Special software has been developed for soft release of formed parts, without using unnecessary stretch of the formed plastic that can affect registration of pre printed plastics.
A Pentium II PC computer, 500+ MHz, 10,000+ MB Hard Drive and VGA monitor display for data setting and reaching, includes the friendliest interface software. This powerful system allow storage of ten's thousands files.
The PC is equipped with a High Speed Modem to enable trouble shooting over the phone.
The machine is equipped with a flashing light that works as follows:
+ Horn: sounds when frame comes out. Sounds when beam is broken in RUN mode.
+ Red Light: "ON" when doors open or Emergency PB is pushed.
+ Green Light: "ON" steady in RUN Mode. Flashing Green when "waiting" for Restart Timer.

The bottom platen has speed controls in both directions, and is mounted on linear bearings and is fitted with a rack and pinion assembly to ensure perfect parallelism.

A powerful and microprocessor controlled air-cooling system with cooling capacity of at least 5,000 CFM.

This machine will be pre-wired for 220/230 VAC, 3 PHASE, and 50/60 HZ.

All components used in our machines are of the highest quality available.

Fully automatic and totally computerized controls. Its controls are the friendliest and most advanced available in the market.

The appearance and the finish of the machine are of European style.

One full year warranty on parts and workmanship.

Electric Mold Temperature Control System:

If the customer prefers to control his mold by electricity, this option is available through the machine's PLC and the PC for interface control. We provided this system free of charge.
The machine is equipped with the right hardware and the appropriate software to provide high accuracy control of the mold temperature. There are two power supply connections for the heaters that should be built into the molds. There are also two connections for type K thermocouples that should be built into the molds. There is special software that sets the 2 zones, and show the correct temperature of the mold.
All the customer needs to do, is to set the Set point temperature in which the mold should be controlled and the PLC will monitor the temperature for you. This system enables feedback control from the mold to the PLC back and forth, till the mold's actual temperature is around the set point within accuracy of +/- 2 °F.

Electrical Modular Quick Change Tool System (Optional):

The mold to be used with the IMD application should be Temperature Controlled otherwise it is impossible to maintain registry and repeatability.
There are 2 ways to temperature-control mold:

1). By circulating water.
2). By electric power.
It is recommended to use the first method if the mold has relatively big draw, or a very complicated shape, or use for forming any material other than Polycarbonate, or combination of all.
It is recommended to use the second method when it is possible, mainly if the material to be used is Polycarbonate, and/or the part is relatively shallow.
ZMD has developed a Modular Electrical Temperature Controlled Quick Change Tool system, microprocessor controlled. This system, can be installed permanently on the IMD machine and be connected and controlled by the PC and machine's PLC (the system we described previously and is a standard in the IMD machine). Now all customer needs to do is to insert an aluminum plate with the cavities (to be supplied by the customer), and the mold will be temperature controlled. It will take seconds to change between tools.
The mold combines advance design of special heaters, up 2 zones thermocouples, ceramic insulation, unique Mold Power Thermocouple Input Connectors, and Mold Power Thermocouple Armored Cable(s). All the connectors are water resistance and have an integral retaining latch for a quick and secure cable connections.

For more information on the IMD technology and application, please click on this link: geimd.com (General Electric Web Site).

Typical Applications:

Cellular Phones
Automotive Components Such As Dashboards, Air Conditioning Panels, Shifting Gear Panels, Wood Grain Trims, etc.
Membrane Switches.
Digital Control Panel of Dish Washer, Washer, Dryer, Air Condition etc.
Electronics panels and housing.
Portable Computers.
Polaroid Cameras.
Computer, Printers Housing and Computer's items with fine graphics.
A quote from a professional magazine: "other growth markets are being discovered almost daily..."