MOLDPRO
| Introduction | Technical Specification | Technical Data | Literature |
| The MoldPro performance is based on the following main features in conjunction with dedicated process know-how for each format: Direct Drive System Three hollow axis AC-servo motors combined with high precision roller gears are used to drive the clamping unit and two hollow axis AC-servo motors are used for the injection unit. These five motors are water cooled and permit high acceleration and high torque. Each motor is equipped with a high resolution encoder to achieve precise positioning. The patented Elamp system is free of clearance to ensure the best repeatability. Together with the PLC-controlled servo amplifiers, which allow simultaneous movements, the all-electric molding machine guarantees high reliability. Clamping Unit The complete system, particularly the clamping unit, was designed by Finite Elements Analysis. Quick opening and closing speeds shorten the cycle times considerably. The direct drive system offers precise positioning and high replication rate due to high acceleration movements. Due to the patented E-clamp system, the parallelism of the mold mounting plates can be influenced. Offset values for each single clamp motor allow adjustments of the substrate thickness variation during operation. Plasticizing Unit The entire unit has been especially designed by SINGULUS MOLDING for optical media applications. Inside the hardened barrel, there is a 28 mm screw with the non-return valve. Each part is surface coated with TiN against wear and corrosion. The barrel is divided into six individually controlled heating zones, with special synchronization software for careful and simultaneous heating to avoid overheating of single zones. The nozzle of the plasticizing unit is actively opened and closed by a pneumatic driven needle shut-off nozzle system. This design ensures a "soft cut" process for best sprue stiffness and high melt quality. Even at high speed cycles the plasticizing time has no influence on cycle time. The permanent contact of the nozzle tip to the sprue bushing leads to very low wear. In addition, melt homogeneity and minimized shot weight variations are achieved by high precision metering control. Multi Format Mold SINGULUS MOLDING has designed a multi format mold which allows the production of substrate thicknesses between 0.2 and 1.5 mm. In combination with the E-clamp system the changeover time from CD with 1.2 mm to DVD with 0.6 mm is no more than the time required for stamper change and readjustment of temperatures. Due to the high precision assembly of the clamp unit and precision ball bearings to guide the tie bars, the mold does not require separate centering. Mold Temperature The temperature control unit consists of a buffer tank, a primary and a secondary circuit. The primary circuit supplies cooling water to the high torque servo motors, the mold mounting platen, the tie bars and the feeding zone of the barrel. The secondary circuit is divided into four mold circuits. Each of these circuits can be precisely adjusted between 20° C and 140° C. All components are specially selected to ensure long lifespan and durability. Magnetically coupled pumps are used for all mold circuits; all other parts, which are in contact with water, are made of either stainless steel or brass to eliminate corrosion. The buffer tank separates the machine from the factory water and is filled with DEMI-water plus an anti-corrosive agent. Servo Take-Out Robot The direct driven servo take-out robot is located at the rear side of the machine and is fixed to the stationary machine platen. It takes the substrate out of the mold and hands it over to the drop-off position for the downstream equipment. The mechanical components and the drive concept of the take-out robot guarantee short cycle times due to fast disc take-out and short mold opening stroke. Other main features are:
The 10-inch colored LC-display gives easy access to the machine operation. The menu is clearly arranged and so far English and German can be selected for a simpler parameter adjustment. Additionally, all important parameters can be monitored, either within one cycle to observe the process behavior, or over 500 shots to judge process stability. Every parameter change is saved in a log-file showing date, time and the old and new parameter values. |  SKYLINE II Inline Replication system for CD/DVD 5      |