توضیحات
(ISBM) دستگاه قالبگیری بادی تک مرحلهای HGY650-V4: راهکار ISBM چهار ایستگاهه سنگین
Engineered by Ever-power | High-Tonnage Clamping | 4-Station Precision for Large Containers
Engineering Overview: Dominating Large-Scale Production
In the heavy industrial sector of polymer processing, stability under pressure is the only metric that matters. As an engineer with two decades of experience fine-tuning دستگاه قالب گیری ضربه ای تک مرحله ای production lines, I present the HGY650-V4. This machine represents the pinnacle of our V4 series, designed specifically for manufacturers requiring massive clamping force and large shot capacities for heavy-wall containers, wide-mouth jars, and high-volume cavitation setups.
The HGY650-V4 operates on a robust 4-station rotary indexing system (Injection, Temperature Conditioning, Stretch-Blow, Ejection). Unlike smaller models, the “650” designation reflects its superior capability to handle substantial projection areas without flashing. It features a reinforced chassis and an advanced hydraulic/servo hybrid system that delivers exceptional locking force. This makes it the ultimate دستگاه ISBM for producing PC water bottles, large PETG cosmetic jars, and pharmaceutical bulk containers where dimensional accuracy and optical clarity are non-negotiable.
Figure 1: The Ever-power HGY650-V4 Heavy Duty Unit
۱. پیکربندی استاندارد فنی
The HGY650-V4 is built to withstand the rigors of high-pressure injection and blowing. We utilize a “Best-in-Class” component strategy, ensuring that every servo, valve, and seal meets global industrial standards.
| سیستم / قطعه | نام تجاری / مشخصات |
|---|---|
| سیستم سروو | Using 4 sets of heavy-duty servo pump systems |
| قدرت موتور سروو | High Torque Configuration (Inovance / WEICHI) |
| سیستم کنترل (PLC) | Inovance / MIRLE (پردازش منطقی پرسرعت) |
| چرخش صفحه گردان | Yaskawa Servo (Japan) + Heavy Duty Reducer |
| ساختار قالب گیری بادی | Dual servo motor mold clamping with high-pressure compensation |
| شیر فشار بالا | پارکر (ایالات متحده آمریکا) |
| سیلندر پنوماتیک | ایرتک (فناوری آلمان/تایوان) |
| کنترل دما | Integrated Control Box (Multi-zone PID control) |
| کنترل هیدرولیک | شیر کنترل فشار YUKEN (تایوان) |
| گرمایش پیچی | Nano-far-infrared energy-saving heating ring (High Efficiency) |
| کنترل واحد تزریق | کنترل تک سیلندر (گزینههای هیدرولیک یا سروو موتور ذوب) |
| Oil Tube | Imported material from Italy |
| Power Config | Optimized for High Output |
2. Machine Parameters: Heavy Duty Capabilities
The HGY650-V4 is designed for maximum throughput. It offers extended strokes and higher clamping forces to accommodate larger molds and more cavities.
| پارامتر | ارزش |
|---|---|
| قطر پیچ | 60mm (Standard) / Options: 55, 65mm |
| ظرفیت تزریق نظری | 680g (High Volume) |
| نیروی بستن تزریق | 650 KN (Approximate Class Rating) |
| نیروی بستن دمیدن | ۳۰۰ کیلونیوتن |
| سکته مغزی قالب بالا | 650 mm |
| سکته مغزی قالب پایین | ۳۵۰ میلیمتر |
| تنظیم دما. ضربه اصلی | ۳۰۰ میلیمتر |
| دما. تنظیم کننده کورس سیلندر | ۳۰۰ میلیمتر |
| سکته مغزی بیرون بر | 200 mm |
| ضربه هسته ای | ۳۵۰ میلیمتر |
| ضربه قالب | 100 + 100 mm |
| حجم مخزن نفت | 600 L |
| ابعاد دستگاه (طول*عرض*ارتفاع) | 6500 x 2500 x 3800 mm (Est.) |
| وزن دستگاه | 18 Tons |
Production Capacity: Cavity & Dimension Matrix
| مقدار محصول (حفرهها) | 2 | 4 | 6 | 8 | 10 | 12 | 14 | 16 |
|---|---|---|---|---|---|---|---|---|
| قطر بطری حداکثر (میلیمتر) | 220 | 130 | 85 | 65 | 50 | 42 | 35 | 30 |
| حداکثر ارتفاع بطری (میلیمتر) | 280 | 200 | ||||||
| قطر گردن (میلیمتر) | 140 | 100 | 60 | 45 | 35 | 28 | 20 | 18 |
| حداکثر حجم بطری (میلیلیتر) | 4000 | 1500 | 800 | 500 | 250 | 150 | 80 | 50 |
| حداکثر وزن بطری (گرم) | 250 | 130 | 70 | 50 | 35 | 25 | 20 | 15 |
Core Technology: 4-Station ISBM Process Flow
The قالبگیری بادی تزریقی تک مرحلهای technology used in the HGY650-V4 is a masterclass in thermal management. By using a rotary table to move the cores between four distinct stations, we ensure the PET retains its Intrinsic Viscosity (IV) for maximum strength and clarity, without the energy loss of reheating.
۱. ایستگاه تزریق
Molten PET is injected into the cavity. The High Clamping Force ensures no flash on the parting lines, even with high-pressure injection required for thin-wall preforms or complex necks.
۲. ایستگاه تهویه مطبوع
The V4 Advantage: The preform is transferred to a conditioning pot. This station homogenizes the temperature—cooling the skin or heating the core—creating the perfect thermal gradient for stretching.
۳. کشش و فوت کردن
A stretch rod extends the preform axially, followed by high-pressure air expanding it radially. The 300KN Blow Clamping Force ensures the mold remains perfectly closed during high-pressure expansion.
۴. بیرون راندن
The finished bottle is stripped from the lip mold and automatically conveyed out. The process is touchless, ensuring hygiene for pharmaceutical applications.
Why Choose the HGY650-V4? Core Advantages
- ✓
Heavy Duty Construction: Designed for large molds and high injection pressures, this machine eliminates “breathing” of the mold during injection, ensuring precise part weights. - ✓
High Cavitation for Mass Production: Capable of running up to 16 cavities for small vials, or 4 cavities for massive 1.5L jars, giving you flexibility across product lines. - ✓
دینامیک انرژی: We use Nano-far-infrared heating rings (10KW+) which penetrate the barrel deeper and faster than standard ceramic heaters, saving ~30% on heating costs. - ✓
Stability: With a substantial machine weight and robust tie-bars, vibration is minimized, leading to longer mold life and reduced maintenance.
تحلیل استراتژیک: سیستمهای یک مرحلهای در مقابل سیستمهای دو مرحلهای
| ابعاد مقایسه | ISBM تک مرحلهای با قدرت همیشگی | دو مرحلهای سنتی (گرم کردن مجدد) |
|---|---|---|
| جریان فرآیند | رزین -> بطری (یکپارچه) | رزین -> پیشفرم -> خنک کردن -> گرم کردن مجدد -> بطری |
| بهرهوری انرژی | بالا (از گرمای نهان تزریق استفاده میکند) | کم (انرژی هدر رفته برای گرم کردن مجدد پریفرمها) |
| کیفیت سطح | بیعیب و نقص (بدون خط و خش و ساییدگی) | خطر خراشیدگی ناشی از حمل و نقل روی پریفرمها |
| مواد قابل استفاده | PET، PETG، PC، Tritan، PPSU، PP | عمدتاً محدود به PET/PP |
| فضای مورد نیاز | جمع و جور (یک دستگاه) | بزرگ (نیازمند واحد تزریق + واحد دمش + انبار) |
| سطح بهداشت | Medical/Food Grade (Touchless) | Standard (Exposed to open air storage) |
کاربردهای صنعتی
Large Format Cosmetics
The دستگاه بطری PET یک مرحله ای excels in producing heavy-wall cream jars (up to 500ml/1L) and shampoo bottles. The high clamping force ensures the thick bases are molded without sink marks.
Pharmaceuticals & Medical
From IV bottles to large bulk tablet containers, the HGY650-V4 ensures precise neck finishes and sterile production environments compatible with cleanroom standards.
PC Water Bottles
The machine’s robust screw and heating system are perfect for processing Polycarbonate (PC) for reusable water bottles, which requires high melt temperatures and injection pressures.
Power System Selection Summary: Ever-power vs. Competitors
Many clients ask how we compare to Japanese giants like ASB or Aoki. The answer is simple: We offer 95% of the capability at 60% of the cost.
ضمانت همیشگی قدرت: Our HGY650-V4 is built with the same global components (Yaskawa, Parker, NSK) found in more expensive machines. We don’t cut corners on hardware; we optimize manufacturing overhead to pass savings to you.
ROI Case: Wide-Mouth Jar Manufacturer
تغییر از خرید پریفرم به تولید داخلی تجهیزات قالب گیری ضربه ای تک مرحله ای تنظیم:
- صرفهجویی در مواد: هزینه پلت تقریباً 25% کمتر از هزینه پریفرم است.
- صرفهجویی در انرژی: Elimination of reheat tunnel saves ~35% electricity.
- دوره بازگشت سرمایه: Typically 12-18 months for a single HGY650-V4 unit due to the high value of large-format containers.
[North America] Extreme Condition Resilience
For our clients in varying climates, the HGY650-V4 is equipped with an advanced hydraulic oil cooling loop. Whether you are operating in the humid summers of Florida or the freezing winters of Minnesota, the system maintains a stable oil temperature of 40-50°C, ensuring consistent clamp pressure and cycle times.
انطباق: دارای گواهینامه CE، مطابق با استانداردهای الکتریکی UL بنا به درخواست.
سوالات متداول مهندس
What is the benefit of the high clamping force?
The 650KN equivalent injection force prevents the mold from “breathing” or opening slightly during high-pressure injection, which is critical for maintaining precise neck dimensions and preventing flash on the parting line.
Can I run Tritan material on this machine?
Yes, the plasticizing unit is designed to handle high-temperature engineering plastics like Tritan, PC, and PPSU effectively.
What is the maintenance schedule?
We recommend a hydraulic oil change every 5,000 hours and a daily check of the lubrication points. The auto-lube system handles most moving parts.
مطالعات موردی جهانی: یادداشتهای میدانی مهندس
USA: Large Bulk Jars
“The HGY650 replaced two smaller machines. We now produce 1L jars with zero flash.” – Production Manager, NJ
Brazil: Premium Cosmetics
“The conditioning station allows us to mold heavy-bottom jars without defects.” – Plant Lead, São Paulo
Germany: Bio-resins
“Handling PLA was difficult until we tried the V4’s precise temp control.” – Engineer, Munich
India: Baby Bottles
“Producing PPSU baby bottles requires high heat. The V4 handles it perfectly.” – Director, Mumbai
Vietnam: Beverage
“Reliable output in a hot climate. The oil cooling is robust.” – Tech Lead, Hanoi
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